See one of the most advanced sausage production plants in the world
The factory in Kashira covers 30% of the Russian fermented salami market.
It is designed to produce up to 100 tonnes of products per day.
It would thus be able to cover half of the consumption of all sausages in the Czech Republic.
Challenges the customer had to face
The need to increase production capacities in connection with EU sanctions (up to 100 tonnes of fermented salami per day)
The desire to build one of the most advanced food plants based on Industry 4.0 principles
It was not possible to achieve sufficient productivity and efficiency by partially expanding the capacity of the existing plants
The need for central management of a large number of production equipment and technologies from suppliers from various countries
Solutions and services provided
Breath-taking increase in production and productivity
In order to rapidly increase the production capacities, Cherkizovo decided to build a brand-new factory in Kashira.
It used this opportunity to deploy state-of-the-art technologies based on Industry 4.0 principles with a view to ensuring high productivity and food safety.
SAP as a clear choice for the area of production
The new plant had to be managed centrally. Cherkizovo has been successfully using the SAP platform across its plants for several years. However, the plant in Kashira was the first plant where the company decided to deploy SAP in production.
The objective was to simplify the system interface and unify the platform for ERP and MES (production management system).
The biggest challenge lied in integration of a diverse set of technologies.
Deployment of the SAP S/4HANA backbone system proceeded in a standard manner. The initial analysis was especially challenging, because apart from Sabris and Cherkizovo, there was a number of technology providers from multiple countries involved in the creation of the solution design.
Even during the other phases of the project, new situations appeared that needed to be solved as needed.
Online management and control of manufacturing processes
Deployment of the S2AP for Food MES solution ensured smooth communication among all robotic equipment (scales, automatic production and packaging lines, etc).
This system effectively manages tasks related to production, logistics, production equipment maintenance and quality management processes based on data collected directly within the processes, which are fully interconnected with ERP data and subsequent evaluated.
The innovative project was awarded the prestigious SAP award
The fully automated plant based on Industry 4.0 principles and managed by the SAP S/4HANA and Sabris S2AP for Food systems received the SAP Innovation Award 2019 in the „Digital Trailblazer“ category.
The award aims to recognise companies using the SAP platform to transform their businesses in terms of development of new business models, use of innovative technologies, opening new markets or fundamental changes in production or delivery of products and services.
Benefits of our solution
Increase in production thanks to full automation (the plant is capable of producing up to 100 tonnes of salami daily).
Only 200 employees work in the fully automated plant and the products are practically never touched by a human hand throughout the entire process.
Ensuring high quality of food and transparency of the manufacturing chain.
The actual use of state-of-the-art technologies is a unique feat and makes Cherkizovo the leader on the Russian food market.
Documents and links
Cherkizovo Group is the largest producer of meat products in Russia. The group is among the three largest players in the poultry, pork and processed meat market and it is also the largest feed producer in the country.
Find more at www.cherkizovo.com