Russer Foods, BUFFALO, NY

CLIENT OBJECTIVES

After moving production from one part of a plant to another in their meat packing
facility, Russer Foods was unable to reach full production capacity and needed
a company to help with revaluating their entire food process through computer
simulation.

Goals of Simulation:

• Define equipment down times and its effect on the food processing system
• Determine utilization of all employees in the system
• Determine utilization of all equipment in the system
• Determine the daily production based on sample product mix
• Make recommendations and test changes in the system

VALUE DELIVERED

Shambaugh & Son was selected to produce a simulation model of Russer’s packaging
room. Problems existed in the way the food processing system was set up and
running, but no one could identify the exact cause. With the use of Real Time Simulation,
Shambaugh & Son was able to answer “what if” questions about the food
processing system layout. This allowed Russer to see their food processing
operation from a new perspective and perform statistical studies on the operation.

Results of Simulation:

• Utilizations of employees were determined and recommendations made on more efficient employee utilization.
• Redundant job positions were identified and recommendations were made on how to change equipment to reduce total number of employees on the line and improve utilization.
• Conveyor layout options were suggested and tested.
• Equipment was unreliable, which produced a chain reaction of down times due to a lack of surge capacity in the whole system. Increasing surge capacity would reduce the impact of a break down on the overall food-processing system.

SCOPE OF SERVICES

Shambaugh & Son ran a complete simulation on the plant food process and analyzed it for redundancies and inefficiency.

BACKGROUND

Russer Foods is part of Zemco Industries, Inc., a division of Tyson Foods. Russer Foods produces meat and deli products. In 2002, the Buffalo plant gained jobs when Tyson transferred work from a closed plant in Maine.

OPERATING COMPANY:
Shambaugh & Son, L.P.

CLIENT:
Russer Foods

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