Design and Implement a traceability system to track the movement of ingredients through the entire product cycle from Raw Ingredient Receiving, through manufacturing and packaging, warehousing and Distribution to the client. Raw ingredients must be able to be traced back to the Raw Ingredient sup[plier and batch number utilising a final product batch number. 

EG Feeds is a rapidly growing organisation in the animal feed industry. They supply over 30 products into the market with a large amount of raw ingredients going into the manufacturing process. Due to good business practice and due to government and industry requirements, traceability of raw materials must be strictly adhered to.

EG Feeds did have some traceability processes in place but needed BOSS to look at the entire system and fill in the gaps.

BOSS analysed the entire system with a focus on traceability. Due to BOSS’s experience with traceability in a manufacturing and distribution environment, we were able to find a great solution.

BOSS identified the critical control points within the process and put in place manual forms to record the necessary data required for traceability (eg. Raw Materials Receiving Checklist to control the batch numbers, quality and quantity of product coming into the Raw Material Store).

We also utilised the current production sheet format and made some adjustments to ensure that the quantities of a specific batched product is controlled throughout the manufacturing process.

BOSS did integration with Microsoft Power BI and Pastel Accounting Software to give EG Feeds the necessary reporting capabilities to easily trace product and raw materials from raw materials through to the consumer. 

Once the solution was complete, BOSS generated all Standard Operating Procedures (SOP’s) for each traceability process and completed training on each SOP to ensure that all staff were trained on the system before implementation.

The process was then implemented.

Key Features and Improvements

• Created user friendly manual forms for critical control points.
• Re-designed the production sheet to incorporate all regulatory requirements for traceability.
• Integration was completed between Microsoft Power BI and Pastel (Accounting Software).
• Generated the required reports to trace product and Raw Ingredients.
• Generated all Standard Operating Procedures.
• Conducted training on all procedures.
• Implemented the process.

• Created a traceability system that satisfies all government and industry requirements.
• Created structure within the product cycle processes to ensure sustainability and resilience of the system.
• Increased the reliability and accuracy of data through-out the product cycle.
• Reduced the time spent on tracing raw materials through integration and reporting.
• Increased Employee accountability through proper control at critical control points.
• Created standardised processes and procedures for all employees to follow to ensure proper production and traceability.
• All staff were trained on the entire system ensuring employee understanding.
• Procedures for system maintenance and corrective action were created and implemented for proper management of the traceability system.

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