NEWS update – “MASTER RENDERER” PROJECT
You will remember that “Master Renderer” is a 2nd “R” multi-year corporate project that will allow the company to fully master the trade knowledge required in order to ensure its customers’ satisfaction, its growth and its long-term development.
Our first steps toward a Master Renderer Qualification Program!
After spending many months developing and structuring all process-related documentation pertaining to the chicken processing line in Montréal, we have laid the groundwork for our Master Renderer Qualification Program. With the implementation of this program, we will be able to provide the required training and documentation to every employee so they can master the knowledge and competencies needed for their position. The skills our employees have acquired over their years at Sanimax will also be recognized.
The Master Renderer Qualification Program covers several aspects:
- Theoretical training, both on basic rendering principles and on the specificities of the raw material transformation process;
- On-site training provided by a certified trainer, with a learning handbook to ensure that all important elements have been covered through knowledge transfer;
- Revised work instructions so that all employees carry out tasks in a consistent manner in order to ensure a standardized operating mode;
- An assessment to identify additional training needs or certify the acquisition of competencies.
Last November, employees assigned to the chicken processing line in Montréal were able to experiment with the first aspect of this program when they attended a brand new on-line training titled “Foundations of Rendering”. Consisting of five 15-minute modules, this training aims to explaining the basic principles of our industry: the products we manufacture, the raw material we transform, and our manufacturing process. It also explains the constraints and challenges related to our operations as well as the importance of quality. This training is now available to everyone through our San T&D system.
As for the on-site training aspect, six trainers have been selected and trained to support the Montréal plant. These trainers will play an important role for the training of new employees and the recognition of competencies.
With the implementation of this first initiative on the chicken processing line in Montréal, we will be able to determine the right recipe for extending the Master Renderer project to all other processing lines in the different Sanimax plants.
Thanks to all employees who contributed and continue to contribute, directly or indirectly, to building the foundations of this major initiative that will allow Sanimax to become THE BENCHMARK of the rendering sector!
Positive results already visible in Montréal
Initiatives for improvement that were identified within the “Processes” and “Technology” components for the chicken processing line in Montreal are almost completed. Many positive impacts are already visible, among which are:
- 18% increase in capacity, which went from 22.5 to 26.5 metric tons of raw material per hour, this without any major investment;
- 0.75% increase in moisture content of our rendered meals (from 4.1% to 4.85%).
In addition, over and above these impacts improving performance, we noted that our operators, supervisors and maintenance staff also benefit. A processing line operating in a much more stable manner simplifies the work of our operators and reduces the number of emergency actions. Equipment blockages and overflows are reduced, which means less physical effort required from our employees and, consequently, fewer risks of accidents for staff. As for members of the Maintenance team, they are able to carry out their maintenance work during shutdowns that are planned daily, which allows us to have equipment in better working condition all week long.
These are just a few of the positive impacts resulting from our MR initiative that is currently ongoing on the chicken processing line at the Montréal plant. As we already mentioned, this is not an easy initiative as it requires a lot of energy and effort from the many people involved. However, this is not only theoretical — we’ve put theory into practice and everyone will be better off!
A good start for the Lévis plant
The Master Renderer project was launched in May at the Lévis plant. A thorough analysis was conducted to identify improvement opportunities, either of the process control or the process in itself. Identified improvement opportunities will be implemented at the standardization stage. Some 50 initiatives will therefore be deployed by the end of January 2018, and their impact should be seen within the first few months of 2018.
Finally, similar to Montréal, a “Daily Operation Review” meeting has been implemented in October. This meeting allows Operation, Process, Maintenance and Control employees to review the last 24 hours of the manufacturing process and take decisions based on this data analysis. This meeting is a great learning and exchange opportunity for all those involved.