Wagg Foods Increase OEE by 30% with OAL Connected

Wagg Foods (IPN) produces high-quality pet food made with quality ingredients at the best possible value. The company cares passionately about the health of our pets which is reflected in their brand values; quality, nutrition and product development.

They pride themselves on their BRC (British Retail Consortium) accreditation, an internationally recognised accreditation that ensures suppliers produce a safe and legal product concurrent with human food quality standards.

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Wagg Foods' Challenges

Wagg Foods were looking for automation solutions protecting their brand from human errors, ensure compliance with retailer’s codes of practice and improve their overall operational efficiency (OEE).

Following a review of suppliers, Wagg Foods approached OAL as their system is tried and trusted in the industry. Andrew Horkan, Continuous Improvement Engineer, explains why Wagg Foods chose OAL:

OAL understood how important brand and reputation was to us. They really took into consideration when planning the installation the opportunities and challenges that we were facing as a company. This high level of understanding is what gave OAL the edge against others.
— Andrew Horkan, Continuous Improvement Engineer

How does the OAL system stop packaging errors?

The OAL Autocoding system links a master database of products, scanners, printers and touchscreen PC’s on the production line. By placing control of the packaging line with your technical team, rather than operators on the line, the risk of errors is removed.

Wagg Foods took a step by step approach to installing the OAL system, initially protecting one packaging line. The system has also been expanded to include their Factory Performance module that provides real-time OEE data.

Control your printers to stop packaging errors

The OAL system controls Wagg Foods’ printers (Domino A320i inkjet printer and Logopak printer) with a two-way connection, managing any risk of printer error.

It is this high-level of security that retailers require to protect the retailer’s brand, manufacturer’s brand and the end consumers against what could be potentially life-threatening errors, particularly if the error was allergen based.

Continuous improvement OEE

Wagg Foods took advantage of the OAL Connected expanded modules to shorten return on investment times. The OAL touchscreens can include OEE data capture and reporting and have been very successful at Wagg Foods:

We have seen an approximate 30% rise in OEE on our line since the install of OEE.
— Andrew Horkan, Continuous Improvement Engineer, Wagg Foods (IPN).

The touchscreen units count products with stoppage (downtime) times. If a stoppage does occur then a reason is selected by the operator on the touchscreen units. The OEE software then transfers all stoppage information across for reporting purposes.

In addition, the touchscreen units can be extended to support real-time, web-based OEE reporting and analysis. The touchscreens will provide accurate information showing current performance to target, together with all lost time reasons.

The automatic system replaces existing manual production logs, providing more accurate and reliable data and reporting. Operational managers can then predict and plan their factory more efficiently as a result of the collated data.

Results

As a result of Autocoding, Wagg Foods have been able to further secure their brand against product recalls due to label and date code errors. They have also improved their overall equipment efficiency as the accurate, real-time data that Autocoding automatically collects aids management in their decision-making.

On the back of this project’s success, they’re now investigating installing Autocoding on more of their lines to further integrate their factory.

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Deborah Stokoe