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 materials were tracked in Excel, and the figure on the sheet rarely matched what was actually on the shelf.
• Expiration dates were checked by hand, so a steady stream of product was spoiling.
• Because no one could see when a product was about to run out, last-minute orders kept pushing costs up.

Production Planning Difficulty:

• Orders came in over WhatsApp and by phone, so there was no single place to coordinate from.
• What to make each day was settled in the morning meeting, which left almost no room to adjust when something went wrong.
• Any hiccup on the production line landed on the customer as a late delivery.

Lack of Quality and Traceability:

• With no batch-number tracking, there was no way to trace back which product had gone to which customer during a recall.
• Hygiene and temperature logs lived on paper, and finding the right file during an audit could take hours.

Our Solution:

Integrated Food ERP System Implementation:

1. Smart Warehouse Management Module
   • Inbound-outbound automation with barcode readers
   • Shelf-life managed automatically on FEFO (First Expired, First Out) logic
   • Automatic supplier notifications once stock hits a critical level
2. Production Planning System
   • An order management portal that let dealers enter their orders online themselves
   • Production schedules generated automatically from current capacity and raw material status
   • Live status updates from the production line through a mobile app
3. Quality and Traceability Module
   • A QR code generated and printed automatically for every production batch
   • Continuous monitoring through integrated digital temperature sensors
   • Automatic preparation of Ministry of Food, Agriculture and Livestock reports

Tangible Results:

Operational Improvements:

• Stock losses down 65% (annual savings of 280,000 TL)
• Spoilage rate cut by 40%
• Stock counts down from 2 days to 4 hours

Increased Efficiency:

• Order-to-production cycle time down from 5 days to 2 days
• Raw material procurement costs down 23%, with emergency orders eliminated entirely
• Time administrative staff spent on inventory tracking down 75%, freeing them for strategic work

Quality and Compliance:

• Full batch-level traceability in place, with audit preparation time shortened by 90%
• Hygiene record-keeping down from 2 hours a day to 15 minutes
• Root cause analysis on customer complaints down from 1 week to 1 day

Financial Impact:

• Total cost savings of 450,000 TL in the first year
• The system paid for itself in 8 months
• Production capacity up 18% on the same resources