SafetyCulture Summit 2021
Simplot Australia is a leading Australian food manufacturer and the home of Australia’s favourite food brands. Learn how Simplot stepped up productivity to meet customer demand
different configurations to suit their products
reduction in start-up delays
Simplot Australia is a leading Australian food manufacturer, stocking supermarket shelves with some of Australia’s favorite food brands. From John West to Birds Eye, it’s a kitchen staple.
One of Simplot’s most popular outputs? Frozen fish. Crumbed fish, battered fish, fish fingers… the list goes on! With its uniquely diverse business outputs came several logistical and operational challenges. Simplot’s manufacturing operations faced capacity constraints — they needed to step up productivity in order to meet consumer demand.
That’s when SafetyCulture entered the picture.
Like most industries, manufacturing is experiencing a rapid shift to digital channels. Simplot is no different. They had rigorous processes in place to ensure the safety and quality of their operations and outputs. But while they had good frameworks in place, their cleaning operations were a significant time drain.
Overnight, Simplot would hand over cleaning operations to an external company to sanitize production lines. They’d have the job done by 6am, but there would always be a two hour gap before production could begin.
Cleaning and sanitizing in the manufacturing industry is no easy feat
With food production, machines have to be taken apart and cleaned regularly
These machines are complex — Simplot deploys 75 different configurations to suit the fish and product they’re working on at the time. Sometimes, the machines aren’t put back together properly, break down or simply aren’t operating as expected. It takes them time to figure out what’s wrong and reset the machine.
Simplot was looking to increase production efficiency and identified those two hours as a key loss in terms of productivity. This is where iAuditor by SafetyCulture came into play. They used the platform to implement pre-start checks, looking to ensure all machinery was set up and cleaned the way it was meant to be. It was more than just a compliance-based inspection — they were seeking to identify frequently failed items that could be causing the lag in the morning changeovers.
With additional capabilities in iAuditor to capture data, track information, and report on outcomes, digital checks aren’t just an efficiency boost for safety audits.
In this case, they found certain machinery proved more challenging to clean and set up to meet best practice standards.
It increases the quantity, consistency and quality of information gathered, allowing Simplot to identify key losses and analyze them for improvements.
Previously with paper-based checks, not only were inspections entirely manual and management-driven, it encouraged a compliance mindset. Here’s the thing with compliance culture — it encourages teams to meet standards rather than exceed them. Simplot wanted to do more.
With iAuditor in the hands of workers on the ground, they had the tools they needed to drive improvements themselves. Workers were able to flag what wasn’t working for them and in turn, what could change to make it better. Using Issues in iAuditor, teams were able to raise ideas and initiate projects, customizing each improvement idea, issue or defect within the platform.
Armed with on-the-ground intel from their workforce, Simplot stepped up their cleaning procedures and standardized them across the board. To ensure the change stuck, they provided mobile training to all their employees around the new and improved processes and scheduled regular inspections in iAuditor to drive consistency. With these steps, they built operational excellence into the drumbeat of the business.
Manufacturing food for the masses is an entirely different ball game to whipping up dinner at home. Temperature becomes key — especially when dealing with chilled or frozen foods that need to reach a certain shelf life. With such diverse outputs, Simplot needed a simple solution to develop effective temperature controls.
SafetyCulture’s temperature and humidity sensors were a valuable addition to their manufacturing area. With it, Simplot could oversee temperature controls with absolute precision and certainty. It reduced the need for manpower and increased peace of mind with real-time visibility — a significant benefit to organizations that produce at scale.
Simplot deploys SafetyCulture temperature sensors on the manufacturing floor to safeguard the wellbeing of staff members, ensuring that the staff are working in conditions that aren't too hot or cold, increasing risk of injury.
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