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Beef processor increases spec accuracy by 30%

A top-tier beef processor collaborated with FloVision AI to tackle yield loss and quality issues affecting striploin primals. Aiming to minimize product and revenue waste, they deployed the FloVision Pro across their facilities. FloVision Pro utilized laser technology & feedback mechanisms to detect and resolve a customer specification that was consistently overtrimmed by 12mm on average.
KEY MODULES
Multicolored blob with two parallel lines over the top edge, indicating lasers. An alert says, "Laser guide for Feature 2 is active"

Laser-Guided Trimming

Multicolored bob with the edge highlighted in teal and measured just over 15mm. An alert says, "Feature 1 is 6mm above spec on this product, view analytics"

Spec Measurement

Multicolored blob has an indication measuring 25mm on the bottom edge. An orange highlight indicates 5mm measured just above the 25mm indicator. An alert says, "Feature 4 target should be increased by 5mm, view analytics"

Spec Optimization

Bar graph with multicolored lines showing loss and gain as percentages for each of four operators. An alert says, "Operator 183 has exceeded benchmarks by +12% today, view analytics"

Workforce Proficiency Analysis

A silhouette of a screen with modular boxes and green, red, and yellow highlights to indicate performance. An alert says, "Feature 3 has been severely out of spec on 21 products this shift, view analytics"

Real-Time Operator Insights

$68,400

identified loss over 12 months

3,420 KG

yield increase over 12 months

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$68,400
in losses identified across 12 months

3,420 KG
gain in yield across 12 months

Ready to learn more?
Contact Us

Challenge

A prominent beef production facility processes 300 head per day, handling diverse customer specifications for every feature and cut. On their highest-margin product, striploin primals, the backstrap is a strip of gristle along the fat side that must be removed to meet customer quality standards. Backstrap removal was specified at 25mm (1 inch) for all customers, except one that demanded a 10mm (.4 inch) backstrap.

Under the previous method, butchers gauged backstraps visually; believing the 10mm spec was too narrow relative to the other requirements, they routinely removed more than necessary. Supervisors seldom checked for precision, and deviations from the 10mm spec were not readily visible. This manual process led to the 10mm customer spec being overtrimmed by 12mm on average, whereas the 25mm backstraps were generally trimmed within 2mm of the target.

Solution

To resolve this quality concern, the beef processor deployed the FloVision Pro, which provides laser trimming guides for butchers, sensors that assess primal features, and a management dashboard with data and trend analytics.

Butchers relied on the FloVision Pro laser guides to precisely measure and trim the backstrap customer spec on every primal. Floor supervisors verified that butchers followed the laser guides, removing the perceived justification for overtrimming. Company management analyzed the data, with particular attention to trends in the 10mm backstraps. The FloVision Pro delivered real-time and daily feedback on the primals and revealed clear patterns that had gone undetected without systematic measurement and monitoring.

Results

The FloVision Pro recaptured substantial yield and revenue for the beef processor. The overtrimming and inability to meet the 10mm customer spec caused a $0.91 yield loss per primal. With 300 primals per day processed to this 10mm spec, rectifying this issue recovered $273.60 per day, and $68,400 yearly on striploin primal backstraps alone for this customer.

"The FloVision Pro system delivered uncompromising, transparent data and feedback loops. When you have a FloVision Pro, it becomes clear what is working and what is not. That truly opens up significant control and value on the boning hall floor."

OPERATIONS MANAGER