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Bellisio Foods Invests in Quality to Beat Expectations

Denis Storey
May 21, 2020

Case Study: Read to discover how Bellisio Foods digitally transformed plant floor quality with TraceGains.

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Case Study: “Plant Floor Quality Digital Transformation for Bellisio Foods”

TraceGains facilitated a digital transformation for Bellisio's quality program, enabling real-time plant floor insight and continuous improvement.

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Food and supplement companies continuously struggle to produce safe, quality products while navigating a regulatory minefield. What's worse, many companies try to do so without taking advantage of technology that can help. Imagine taking a cross-country road trip with an outdated paper map rather than using your GPS.

Most food and supplement manufacturers still track plant floor information on paper forms, which invariably end up in three-ring binders stored somewhere only to collect dust. At that point, no one can analyze the data contained within those documents to spot emerging trends or problems – like equipment failures, downtime, or product defects that are plaguing the production process. If anyone makes a mistake – and humans usually do – and it's not detected early, it can cause expensive problems downstream and even grind production to a halt.

The executives at Bellisio Foods were facing these problems and investigated several solutions before choosing TraceGains. Before, paper forms weighed down the production line, perpetuating inaccurate data capture. At the same time, unreliable resource planning led to operational inefficiencies, and a lack of procedural governance threatened overall quality standards.

Bellisio's shop floor employees operate a massive one-million-square-foot manufacturing facility and maintain 20 production lines, often running on two, and sometimes three shifts. As a result, employees struggled to collect and manage shop-floor data, maintain standard operating procedures, and respond to daily changes in the production environment.

TraceGains helped transform Belliso's plant floor operations, replacing paper forms with standards-based electronic ones, empowering shop-floor employees with training programs, and automated checklists. All documentation is digitized and used to inform configurable dashboards that provide real-time reporting on the status of employees, processes, and quality production measures.

A Simple, Single Solution

Bellisio's solution was to authorize their shop floor employees with process automation, education, and real-time insight with Quality Management from TraceGains.

With so many production lines in operation simultaneously, there was a tremendous amount of data to collect. Unfortunately, Bellisio employees were drowning in paper forms.

"What would normally be hours of copying paper and creating paperwork for the following day now only takes about 15 minutes using TraceGains," Bellisio Foods QMS Supervisor Matthew Leach explained. "There's no time wasted searching for information or documents because everyone on the team has instant access to all of it with any device."

With Quality Management, paper forms become digital records, and now FSMA and GFSI electronic forms align perfectly with Bellisio's standard operating procedures. With a new automated system, all of Bellisio's data is in a single location, and dynamic dashboards provide teams with immediate insight into what's happening on the plant floor.

Read more about how TraceGains helped Bellisio Foods streamline operations while improving visibility into plant operations in this case study.