Kazumasa Kosuga (1), Toshihiko Nagaoka (1); (1) Asahi Breweries, Ltd., Suita, Japan
Brewhouse Operations
Poster
In recent years, we have launched more than 50 types of beer per year
due to diversification of Japanese consumer preferences. To address
these preferences, our domestic breweries engage in high-mix, low-volume
production. To produce a large variety of wort, brewery workers
manually add a wide range of raw materials during each stage of the wort
production process (mash kettles, mash tuns, wort kettles, whirlpools,
enzyme tanks, and hop hoppers). During this process, the following risks
are of particular concern: 1) raw material type errors; 2) raw material
quantity errors; 3) use of non-conforming raw materials, such as
expired and non-conforming materials; and 4) failure to order the
required raw materials due to an increase in the number and variety of
raw materials handled. To avoid these risks, we introduced an input
error prevention system that uses QR codes. The system consists of three
stages: a) raw material ordering; b) raw material receipt; and c) raw
material input. a) Raw materials to be ordered are searched and
identified using the production plan and an input error prevention
system stock list, and the materials are ordered (as a solution to 4
above). b) Upon receipt, raw material lot numbers and expiration dates
are recorded in the input error prevention system, and QR code labels
are issued. The labels are attached to the raw material containers,
which are then stored in inventory. The system prevents acceptance of
raw materials that are not included in material purchase order lists. c)
Raw materials displayed on an input error prevention system portable
terminal are input in accordance with the production plan. Portable
terminals are used to read the QR codes on the material containers and
those on the equipment into which the materials are to be input. The raw
material type must correspond to that indicated in the production plan
for input to be possible. When the predetermined quantity of raw
materials is input, a signal is sent to a preparation process monitoring
system, and the preparation process continues. If the QR code label of a
non-predetermined material is detected, a warning is sent to the
portable terminal, and the preparation process is halted. This system
prevents the use of non-conforming materials (a solution to 1, 2, and 3
above). In addition, because work content information is displayed on
portable terminals, even junior staff members are able to identify and
add raw materials using the same procedures as experienced workers, and
the management of work and material use histories is possible.
Kazumasa Kosuga graduated from the Department of Electrical
Engineering, Doshisha University and joined Asahi Breweries, Ltd. in
1999. Kazumasa worked at the Hakata brewery from 1999 to 2003, the
Production Technology Center from 2003 to 2005, the Ibaraki brewery from
2005 to 2007, the Fukushima brewery from 2007 to 2010, Asahi Group
Engineering Co., Ltd. from 2010 to 2013, and the Production Technology
Center from 2013 to the present.
