Page 65 - FoodFocusThailand No.199 October 2022

SMART PRODUCTION

The root causes of temperature abuse of raw 8. Documents are incomplete. In most cases, import files
chicken and non-compliance with regulations can be contain incomplete information. Sometimes the form for
identified through the Pareto Principle and Why-Why establishments of health service (AKA Sor Por Sor.2 Form) does
Analysis. As a result, the problem is found to be rooted not have an analysis certificate or the signature of in-house
in the absence of the following factors: logistics veterinary.
planning, temperature recording in the receiving steps,
GPS tracking, adequate scheduling for raw material Pareto Analysis of the Problems Identified in the
reception, and effective cold chain management during Receiving Process of Raw Chicken
transportation from supplier to manufacturer. The Based on the supplier-related complaints, the Pareto Analysis is
corrective measures that must be used to address used as a tool to rank the problems found in the receiving process
these problems may include, for example, lean concept of raw chicken, ranging from the most to the least frequent cases.
of loading steps and the integration of a data logger As illustrated in Figure 1, based on the complaints against all raw
with IoTs so that raw material temperature can be material suppliers from the manufacturing companies in the case
tracked in every step of the cold chain. These solutions study, the most frequently detected issue is temperature abuse,
aim to prevent the aforementioned problems and curtail which involves non-compliance with the pre-established
the risks of a raw material return due to temperature requirements. In their respective order, the next frequently found
abuse. problems are the presence of foreign bodies in raw material, use
In a case study looking into the problems originating of clear plastic bags, wrong product size, flawed appearance,
from raw chicken suppliers, the data collected between bad odor, incomplete documents, and mixed products.
January 2017 and December 2020 show that supplier-
related complaints filed by the manufacturers include Why-Why Root Cause Analysis
the following issues: Based on the ranking of the problems during the receiving steps
of raw chicken, temperature abuse is the top non-compliance
1. Clear plastic bags are used as containers. problem. The root causes are identified via the Why-Why Analysis,
The manufacturers in the case study prohibit their which entails a brainstorming activity of all parties involved in the
suppliers from packing chicken raw materials in process, such as on-site workers, supervisors, and managers of
transparent plastic bags because, in case of tear or
breakage, a hardly visible, torn piece of plastic may
become mixed up with raw materials and passed onto
the manufacturing phase.
2. Visible, the flawed appearance of raw chicken,
such as tear, or bruise, is detected.
3. The raw material’s temperature exceeds the
established standard. For instance, the raw material’s
temperature during the inspection and reception
processes is higher than the standard temperature of
-18 degree Celsius.
4. Foreign bodies are detected. For example, the
raw material may contain a particular type of foreign
objects, such as wood, plastic, glass, string, hair, rock,
or aluminum fragment.
5. The raw material has a bad smell. Chicken
meat may exude a natural odor, which is normal.
However, other types of smell, such as stale or off odor,
may indicate an abnormal condition.
6. The raw material has the wrong size. The
product’s size does not comply with the specified
requirements, such as having an insufficient or
excessive length.
7. The raw material gets mixed up with other
products. For example, chicken wing is mixed up with
chicken breast, or chicken breast comes packaged
with chicken tenderloin.

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