Produce, step 5 of 6
More output from the same lines, labor and shifts.
Floor Optimizer gives you live, station-level visibility into every line, from raw intake to finished pack, so losses surface while there’s still time to fix them.
How it works
Sees
Live rates per station, fill weights, yields and defects.
Weighs
Where the hours and the product are going, by SKU, line, crew and time of day.
Moves
Re-sequences runs, recommends crew rebalancing, and flags drift before product goes out the door.
Know a line is behind at 9 AM, not at the end of the shift.
Run-time losses hide in minor stops, slow speeds, giveaway and yield drift. They usually show up in the end-of-shift numbers, after the hours are gone. Food lines typically run at 45–65% overall equipment effectiveness (OEE); best-in-class lines run above 75%. Source: published food-line OEE study (AIP Conference Proceedings, 2024).
Your kind of operation
- For a processor
- Run sequencing and changeovers.
- For a packhouse
- Crew and line balance across shifts.
Where the value shows up
+11%
throughput from line optimization
Measured: live customer result
5–10%
more output per labor hour
Measured at customers
Close the OEE gap
Minor stops, speed and yield attacked, from the industry norm toward best-in-class.
Less giveaway
Fill and weight variance on fixed-weight packs from around 5% to under 1%. Source: industry giveaway benchmarks.
Less yield loss
Ingredient usage and process yield tracked live, so drift is caught before it gives product away or breaks the label spec.
Less rework
Defects and off-spec product trended by SKU, line, crew and time of day, so root causes get fixed.
Floor labor figures measured at customer sites.
What it connects to
- Line machines and sensors
- Checkweighers
- Plant-floor systems and line controllers
- Labor and timekeeping
- ERP work orders
- Grading and sorting results
Questions
Do we need new sensors?
No. It works from what your lines report today; new sources are optional.
Does it change how crews work?
It recommends crew rebalancing; your supervisors decide.
How quickly does it see a problem?
As fast as the line reports it, up to real time.
How many recoverable hours are hiding on your lines?
We’ll find them with you, station by station.