Food Services

From Manual Warehouse to Smart Supply Chain

Stock losses decreased by 65%, and the spoilage rate dropped by 40%.

Client Profile: Mid-sized Food Production Company

Area of Activity: Deli products and ready-to-eat meal production
Number of Employees: 120 people
Monthly Production: 45 tons

Problem:

Inventory Management Crisis:

• Raw material stocks were tracked in Excel, leading to discrepancies between physical stock and records.
• Expiration dates were manually controlled, resulting in continuous spoilage.
• Emergency orders increased costs due to the inability to foresee when products would run out.

Production Planning Difficulty:

• Orders were received via WhatsApp and phone, making coordination impossible.
• What to produce on which day was decided in morning meetings, lacking flexibility.
• Disruptions on the production line led to delivery delays.

Lack of Quality and Traceability:

• Batch number tracking was not possible, making it impossible to identify which product went to which customer during recalls.
• Hygiene and temperature records were kept on paper, taking hours to find files during audits.

Our Solution:

Integrated Food ERP System Implementation:

1. Smart Warehouse Management Module
   • Inbound-outbound automation with barcode readers
   • Automatic shelf-life management with FEFO (First Expired, First Out) logic
   • Automatic supplier notifications at critical stock levels
2. Production Planning System
   • Dealers gained the ability to enter online orders via an order management portal
   • Automatic production schedule generation based on production capacity and raw material status
   • Instant status updates from the production line via a mobile application
3. Quality and Traceability Module
   • Automatic QR code generation and labeling for each production batch
   • Continuous monitoring with digital temperature sensor integration
   • Automatic preparation of Ministry of Food, Agriculture and Livestock reports

Tangible Results:

Operational Improvements:

• Stock losses decreased by 65% (annual savings of 280,000 TL)
• Spoilage rate reduced by 40%
• Stock count duration reduced from 2 days to 4 hours

Increased Efficiency:

• Order-to-production cycle time decreased from 5 days to 2 days
• Raw material procurement costs decreased by 23% (emergency orders eliminated)
• Time spent by administrative staff on inventory tracking decreased by 75%, enabling focus on strategic tasks

Quality and Compliance:

• Full batch-based traceability achieved, audit preparation time shortened by 90%
• Hygiene record-keeping time reduced from 2 hours per day to 15 minutes
• Root cause analysis time for customer complaints reduced from 1 week to 1 day

Financial Impact:

• Total cost savings of 450,000 TL in the first year
• System investment paid for itself in 8 months
• Production capacity increased by 18% with the same resources