Case Study
A Sea of Quality: How Jealsa Scaled Production Capacity with TrakSYS
TrakSYS helped Jealsa create an additional 200,000 cans of production per day.
Jealsa achieved a 15% improvement to OEE in the production area within just 3 months of its TrakSYS rollout.
TrakSYS helped Jealsa reduce the cost of sold goods by 10% while increasing traceability and packaging capacity.
Our project had very ambitious goals: improving manufacturing productivity, product tracking, and integration with SAP. TrakSYS rapidly helped us better understand our assets' productivity, standardize plant floor processes, and close the gap between the plant floor and business systems in real time.
The Company
Created in 1958 by Jesús Alonso Fernández, the Jealsa Group is a Spanish food company with more than 60 years of experience in the canned fish and seafood market. Based out of Boiro, Jealsa has grown to be one of the top manufacturers of canned food in Spain and Europe, having created the first easy-open canned products in Spain.
The Challenge
As demand for its products continued to increase, Jealsa needed to increase production capacity and efficiency. The company faced siloed data, disparate implementations, and no real-time production data or KPIs to guide decision-making.
The Solution
ASM and the team at Jealsa designed and implemented an extensive TrakSYS rollout, using an on-site server to house TrakSYS, its applications, and Jealsa-specific production data. The software was implemented across 4 cleaning lines, 8 filling and sealing lines, 8 sterilizers, and 5 packaging and case packing lines, integrated with Jealsa's ERP system (SAP) for real-time information exchange.
Through integration with the sterilizer, TrakSYS collected pallet IDs, calculated sterilization cycle times, captured temperatures, and triggered alarms when a rule was violated, while TrakSYS-powered statistical process control (SPC) tracked average weight against target weight in the packaging area.
The Impact
Utilizing TrakSYS, Jealsa was able to create an additional 200,000 cans per day, improve traceability by 15%, and increase packaging capacity by 10%, alongside a 20-point OEE improvement in packaging.
The company also increased the capacity of its sterilization areas by 34%, achieved a 15% improvement to OEE in the production area within 3 months, and reduced the cost of sold goods by 10%, all while facilitating operator engagement and establishing visual management for operational productivity.
Get the Full Jealsa Story
See how TrakSYS helped Jealsa scale production capacity, boost OEE, and close the gap between the plant floor and SAP.
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