Loading
Rockwell Automation Home
  • Industries
    • Industries Chevron RightChevron Right
      • Automotive & Tire
      • Cement
      • Chemical
      • Entertainment
      • Fibers & Textiles
      • Food & Beverage
      • Household & Personal Care
      • Infrastructure
      • Life Sciences
      • Marine
      • Metals
      • Mining
      • Oil & Gas
      • Power Generation
      • Print & Publishing
      • Pulp & Paper
      • Semiconductor
      • Water Wastewater
      • View All
    Industries
    Case StudyRockwell Automation's case studies Case Studies DistributorDistributor How to Buy EventEvent Events
  • Capabilities
    • Capabilities Chevron RightChevron Right
      • The Connected Enterprise®
      • Consulting & Integration Services
      • Cybersecurity
      • Digital Transformation
      • Industrial Analytics
      • Industrial Automation & Control
      • Industrial Maintenance & Support
      • Industrial Networks
      • Lifecycle Services
      • Machine & Equipment Builders
      • MES Solutions
      • Process Solutions
      • Safety Solutions
      • View All
    Capabilities
    Blogs DistributorDistributor How to Buy EventEvent Events
  • Products
    • Hardware Chevron RightChevron Right
    • Software Chevron RightChevron Right
      • Circuit & Load Protection
      • Condition Monitoring
      • Connection Devices
      • Distributed Control Systems
      • Drives & Motors
      • Energy Monitoring
      • Human Machine Interface
      • Independent Cart Technology
      • Industrial Computers & Monitors
      • Input/Output Modules
      • Industrial Control Products
      • Lighting Control
      • Motion Control
      • Motor Control
      • Networks Security & Infrastructure
      • Packaged Solutions
      • Power Supplies
      • Programmable Controllers
      • Push Buttons & Signaling Devices
      • Relays & Timers
      • Safety Instrumented Systems
      • Safety Products
      • Sensors & Switches
      • Signal Interface
      • View All Hardware Products
    • DesignSuite
      • Dynamic Digital Twin Software
      • Studio 5000 Design Software
    • OperationSuite
      • FactoryTalk Edge Gateway
      • FactoryTalk Batch
      • FactoryTalk Historian
      • FactoryTalk View - HMI Software
      • FactoryTalk Metrics
    • MaintenanceSuite
      • FactoryTalk Analytics for Devices
      • FactoryTalk AssetCentre
      • FactoryTalk Emonitor
      • FactoryTalk Network Manager
      • FactoryTalk TeamONE
      • Fiix CMMS
    • InnovationSuite
      • Augmented Reality
      • FactoryTalk Analytics
      • MES
      • ThingWorx IIoT Platform
    Products
    Find Products by Our Brands: Allen-Bradley FactoryTalk
  • Support
    • Product Support Chevron RightChevron Right
    • Documentation Chevron RightChevron Right
    • Knowledgebase Chevron RightChevron Right
    • Training Chevron RightChevron Right
    • Downloads
      • 2D & 3D Drawings
      • Activations
      • Add-on Profiles
      • Application Code Libraries
      • Compatibility & Downloads
      • Drivers & Firmware
      • Electronic Datasheets
      • EPLAN Macros
      • Sample Code Library
      • Software Patches
      • View All
    • Selection & Configuration
      • Control Systems Configuration Tools
      • Procurement Specifications
      • ProposalWorks Proposal Builder
      • Global Short-circuit Current Ratings Tool
      • Integrated Architecture Builder
      • View All
    • Compatibility & Migration
      • Migration & Modernization
      • Lifecycle Status
      • Product Replacement Lookup
      • View All
      • Technical Documentation Center
      • Technical Specifications
      • Product Certifications
      • Product Drawings
      • Release Notes
      • Literature Library
    • Support Center
      • Support Options
      • Search for Answers
      • Chat Online
      • Call Us
      • View All
    • Online Forum
      • My Inbox
      • My Favorites
      • My Subscriptions
      • View All
    • My TechConnect
      • Chat History
      • Service Ticket History
      • Manage Your Favorite Answers
      • Field Service Request
      • View All
      • E-Learning Courses
      • Training Workstations
      • Training Calendar
      • View All
    Support
    Contact Us HelpHelp Get Support LaunchpadTools and applications View All Tools
  • Company
    • Events Chevron RightChevron Right
    • News Chevron RightChevron Right
    • Careers Chevron RightChevron Right
    • PartnerNetwork Chevron RightChevron Right
    • About Us Chevron RightChevron Right
    • Featured Events
      • Automation Fair
      • Process Solutions User Group
      • Smart Machine Workshops
      • VirtualConnect: Smart Manufacturing
      • View All
    • Webinars
      • Live
      • On-Demand
      • View All
      • Blogs
      • Case Studies
      • Automation Today
      • Podcasts
      • Press Releases
      • Media Contacts
      • View All
      • View Jobs
      • Teams & People
      • Hackathon
      • Employee Video Spotlight
      • Authorized Distributors
      • Encompass Product Partners
      • Licensed Developers
      • OEM Partners
      • Strategic Alliance Partners
      • System Integrator Partners
      • PartnerNetwork Portal
      • View All
      • Our Brands
      • Our Community
      • Our History
      • Integrity & Sustainability
      • Investor Relations
      • View All
    Company
    ProductivityProductivity Investor Relations
  • Sales
  • Sales
  • View All Industries
  • View All
  • View All
  • View All
  • View All
  • Automotive & Tire
  • Cement
  • Chemical
  • Entertainment
  • Fibers & Textiles
  • Food & Beverage
  • Household & Personal Care
  • Infrastructure
  • Life Sciences
  • Marine
  • Metals
  • Mining
  • Oil & Gas
  • Power Generation
  • Print & Publishing
  • Pulp & Paper
  • Semiconductor
  • Water Wastewater
  • View All
  • The Connected Enterprise®
  • Consulting & Integration Services
  • Cybersecurity
  • Digital Transformation
  • Industrial Analytics
  • Industrial Automation & Control
  • Industrial Maintenance & Support
  • Industrial Networks
  • Lifecycle Services
  • Machine & Equipment Builders
  • MES Solutions
  • Process Solutions
  • Safety Solutions
  • View All
  • Circuit & Load Protection
  • Condition Monitoring
  • Connection Devices
  • Distributed Control Systems
  • Drives & Motors
  • Energy Monitoring
  • Human Machine Interface
  • Industrial Computers & Monitors
  • Input/Output Modules
  • Industrial Control Products
  • Lighting Control
  • Motion Control
  • Motor Control
  • Networks Security & Infrastructure
  • Packaged Solutions
  • Power Supplies
  • Programmable Controllers
  • Push Buttons & Signaling Devices
  • Relays & Timers
  • Safety Instrumented Systems
  • Safety Products
  • Sensors & Switches
  • Signal Interface
  • View All Hardware Products
  • View All
  • View All
  • Technical Documentation Center
  • Technical Specifications
  • Product Certifications
  • Product Drawings
  • Release Notes
  • Literature Library
  • View All
  • Training Workstations
  • Training Calendar
  • View All
  • View All
  • Blogs
  • Automation Today
  • Podcasts
  • Media Contacts
  • View All
  • View Jobs
  • View All
  • Authorized Distributors
  • Encompass Product Partners
  • Licensed Developers
  • OEM Partners
  • System Integrator Partners
  • PartnerNetwork Portal
  • View All
  • Our Brands
  • Our History
  • Investor Relations
  • View All
  • iTRAK Intelligent Track Systems
  • MagneMover Lite Intelligent Conveyor System
  • QuickStick Intelligent Conveyor System
  • View All
  • Dynamic Digital Twin Software
  • Studio 5000 Design Software
  • FactoryTalk Edge Gateway
  • FactoryTalk Batch
  • FactoryTalk Historian
  • FactoryTalk View - HMI Software
  • FactoryTalk Metrics
  • FactoryTalk Analytics for Devices
  • FactoryTalk AssetCentre
  • FactoryTalk Emonitor
  • FactoryTalk Network Manager
  • FactoryTalk TeamONE
  • Fiix CMMS
  • Augmented Reality
  • FactoryTalk Analytics
  • MES
  • ThingWorx IIoT Platform
  • 2D & 3D Drawings
  • Activations
  • Add-on Profiles
  • Application Code Libraries
  • Compatibility & Downloads
  • Drivers & Firmware
  • Electronic Datasheets
  • EPLAN Macros
  • Sample Code Library
  • Software Patches
  • View All
  • Control Systems Configuration Tools
  • Procurement Specifications
  • ProposalWorks Proposal Builder
  • Global Short-circuit Current Ratings Tool
  • Integrated Architecture Builder
  • View All
  • Migration & Modernization
  • Lifecycle Status
  • Product Replacement Lookup
  • View All
  • Support Options
  • Search for Answers
  • Chat Online
  • Call Us
  • View All
  • My Inbox
  • My Favorites
  • My Subscriptions
  • View All
  • Chat History
  • Service Ticket History
  • Manage Your Favorite Answers
  • Field Service Request
  • View All
  • My Training
  • View All
  • Automation Fair
  • Process Solutions User Group
  • Smart Machine Workshops
  • VirtualConnect: Smart Manufacturing
  • View All
  • Live
  • On-Demand
  • View All
  • Digital Transformation at Norbord
  • View All
  • Brighter, More Flexible Tower Light Now Available from Rockwell Automation
  • Delphi Award Received For Asset Management
  • Internal Bypass Expands Smart Motor Functionality
  • New IaaS Bundle Eases Industrial Networking
  • Rockwell Automation Names Sebastien Grau as Regional Sales Director for Middle East, Turkey and Sub Saharan Africa
  • Expanded Power Range for PowerFlex 6000 MV Drives
  • Studio 5000 Software Update Optimizes Productivity
  • FLEX 5000 I/O Modules Bring Greater Productivity and Flexibility to a Connected Enterprise
  • New Cable-Pull Switch Enhances Industrial Safety
  • Instant Industrial Device Analytics
  • Rockwell Automation to name Al Ghandi Electrical & Automation as Authorised Distributor in the UAE
  • Rockwell Automation to Broaden Connected Enterprise Consulting Expertise with Acquisition of Kalypso
  • Single-Control Multi-Well Pad Solution Cuts Costs
  • Advanced Light Curtain System Improves Flexibility and Safety
  • Automation University
  • Rockwell Automation to Showcase the ConnectedProduction Solutions and Premieres its ThinManager Software at ADIPEC 2018
  • Safe Torque Off Option Simplifies Machine Design
  • Machine Performance Analytics Bring OEM Expertise Into Producer’s Digital Environment
  • Software-Powered Connected Services
  • New Managing Director of Rockwell Automation for Sub-Saharan Africa announced
  • Rockwell Automation Simplifies Analytics for Industrial Productivity
  • New Managing Director of Rockwell Automation for Sub-Saharan Africa announced
  • Securely Deploy Cloud and Mobile Technologies with New Network Guidance
  • Rockwell Automation drive system selected for Sumitomo Rubber’s rubber mixers
  • PlantPAx DCS Roadmap
  • View All
  • Students & New Grads
  • View All
  • Hackathon Use Case for Manufacturing Optimization
  • Hackathon Use Case for Sustainability
  • Hackathon Use Case for Visual System Modernization
  • Hackathon Use Case for Dynamic Filtering
  • View All
  • 24toCode Event Recap - Winter 2019
  • 24toCode Event Recap // IT Internal Hackathon
  • Meet the 2019 IT Summer Interns
  • 24toCode Promo Video
  • Harbor View Plaza Ribbon Cutting
  • Check Your Blind Spots Mobile Tour at Rockwell Automation
  • Mechanic & Tool Apprenticeship at Rockwell Automation
  • Working at Rockwell Automation in Karlsruhe
  • Summer Internships at Rockwell Automation
  • The Intrapreneurial Skills Accelerator at Rockwell Automation
  • Makers Wanted
  • #LifeatROK w Katowicach
  • IT Summer Internship Program
  • #LifeatROK with Diogo
  • View All
  • Cisco
  • Endress+Hauser
  • FANUC
  • Microsoft
  • Panduit
  • View All
  • Our Focused Giving
  • STEM Education
  • Lifelong Learning
  • View All
  • Sustainability Report
  • Our Commitment to Diversity, Equity and Inclusion
  • Environmental, Health, & Safety
  • Ethics & Compliance
  • Global Supply Chain & Sourcing
  • Product Environmental Compliance
  • Quality Management Systems
  • Trust & Security
  • Workforce of Tomorrow
  • View All
Case StudyRockwell Automation's case studies Case Studies DistributorDistributor How to Buy EventEvent Events
Blogs DistributorDistributor How to Buy EventEvent Events
Find Products by Our Brands:
Allen-Bradley FactoryTalk
Contact Us HelpHelp Get Support LaunchpadTools and applications View All Tools
ProductivityProductivity Investor Relations
  • Literature LibraryLiterature Library
    Literature Library

    Access technical and commercial publications for hardware and software products, applications, services and solutions.

    PCDCProduct Compatibility and Download Center
    Compatibility & Downloads

    Find downloads including firmware, release notes, associated software, drivers, tools and utilities.

    KnowledgebaseKnowledgebase Support Center
    Knowledgebase

    Browse the database of questions and answers on a variety of products and technologies.

    Product ConfiguratorProduct Configurator
    Product Configurator

    Configure and select products rapidly.

    Software SubscriptionsSoftware Subscriptions
    Software Subscriptions

    One stop shopping for software and subscription services.

    2D & 3D Drawings Bill of Materials CrossWorks Electronic Datasheets Motion Analyzer My Equipment My Training E-Learning Portal Product Lifecycle Status Product Registration Product Selection Toolbox Repairs Sample Code Library Software Activations View All
    Tools
    UserUser Sign In/Create an Account
  • User Account User
Tools
Literature LibraryLiterature Library
Literature Library
PCDCProduct Compatibility and Download Center
Compatibility & Downloads
KnowledgebaseKnowledgebase Support Center
Knowledgebase
Product ConfiguratorProduct Configurator
Product Configurator
Software SubscriptionsSoftware Subscriptions
Software Subscriptions
2D & 3D Drawings Bill of Materials CrossWorks Electronic Datasheets Motion Analyzer My Equipment My Training E-Learning Portal Product Lifecycle Status Product Registration Product Selection Toolbox Repairs Sample Code Library Software Activations View All
Case Study
Recent ActivityRecent Activity

Leading U.S. Pork Producer Optimizes Supply Chain

Share This:

LinkedInLinkedIn
TwitterTwitter
FacebookFacebook
PrintPrint
EmailEmail
Main Image

Challenge

  • Determine the best regional business structure for optimal oversight and lowest cost
  • Automate logistics to leverage real-time capacity at contracted sites, facilitate site selection and reduce operating costs

Solutions

  • Arena® Simulation Software - Simulation provides flowchart modeling methodology, flow/continuous process modeling, graphic dashboards, scenario analysis, custom templates and reports

Results

  • Improved Space Utilization - Weekly flow and capacity updates capture lowest regional yardage costs and space availability, cutting costs and enhancing flexibility
  • More Informed Business Decisions - Scenario analysis feature rapidly integrates complex variables, facilitating fast and accurate operating decisions
  • Extended Forecasting Ability - Automated flow modeling extends forecasting from one to five years

Background

From the popularity of baby-back ribs to the national obsession with bacon, Americans have an avid appetite for pork. The Maschhoffs -- the largest family-owned pork producer in the United States – helps satisfy that hunger from its headquarters in Carlyle, Illinois. In 2014, the company sold nearly $1 billion in pork -- enough to feed over 16 million average consumers annually.

Like many major agricultural operations, The Maschhoffs started with a single family farm. For five generations, The Maschhoffs grew row crops and raised cattle. But brothers Ken and Dave Maschhoff returned to the farm home from college with bigger dreams. In 1991 they bought their parents' share of the business and began expanding the operation.

Today, The Maschhoffs' pig operation employs about 1,500 employees. Contracting with production partners – about 550 family farmers across the Midwest – the company sells about 5 million live hogs annually. The buyers are packing plants and food producers such as Cargill, Hormel Foods and Farmland.

The Maschhoffs provide pigs and feed to their production partners, and pay the farmers for the time, labor and space necessary to raise the hogs.

Challenge

Running any large farming operation is a complex undertaking. That's particularly true in modern pig raising, which entails a continuous logistics challenge: the need to move pigs to specialized farm sites at different stages of growth.

Once small farmers commonly took on the entire farrow-to-finish operation – breeding sows, weaning piglets, growing feeder hogs and preparing them for market or “finishing.”

But rising transportation and feed costs – along with the complexities of hog genetics and health risks – have forced many smaller farms to specialize and contract their services to large producers.

And so, a large operation like The Maschhoffs must contend with a continuous flow of pigs between different types of farms – from sow (or breeding) facilities, to weaning, feeding and finishing facilities.

“We have 73 different sow farms, and when piglets grow to about 21 days old, we need to start looking for the best space to house them,” explained Morgan Dugan, director of supply chain management and logistics for The Maschhoffs.

Weaning farms are specially equipped for young pigs, with pen sizes that can accommodate the sows and the piglets. In six to 10 weeks, the young pigs are moved to finishing facilities that can accommodate the larger size animals.

“We were having a hard time measuring all the impacts of our space decisions,” said Dugan, who oversees the transport of 700 to 800 trailer truckloads of live pigs each week.

The company's logistical system consisted of Excel spreadsheets, providing only a small window into how many pigs were flowing through their system at any one time. Without more precise analytical tools, they couldn't project how much farm space they'd need in the next month, for instance, or compare the costs of their owned and leased facilities.

The Maschhoff's analytical and predictive limitations became even more apparent when company leaders decided to reorganize the business from a national to a regional management structure.

The company wanted to move to a distributed leadership model, with smaller geographic territories, to give managers a better line of sight into the business' leased assets and contracted farming operations.

The problem? Without modeling and predictive technology, they couldn't reliably determine the optimal number of divisions, or which facilities should be included in each region.

“We could ask a flow planner to project our flow to sites for the next 52 weeks, but that would require somebody three days to complete,” Dugan said. “And you can't really ‘war game' different options if you have to wait that long,”

Solution

The Maschhoffs analyzed different supply-chain modeling packages in tandem with a group of graduate business students from Washington University at St. Louis. As part of a special project with the company, the students evaluated dozens of solutions. Arena®software was their No. 1 recommendation.

“The Arena application provided total flexibility that allowed us to model anything we needed,” Dugan said. “We also felt we'd get a good return on our investment.”

Arena's flowchart modeling methodology made it easy to build a logistics process flow. Drag-and-drop elements and structures simplify simulation building and visualization. The software also features built-in dynamic dashboards for model analysis.

The Rockwell Automation team, who began immersing themselves in the daily operations of the business, spent weeks on-site at the Carlyle headquarters to understand The Maschhoffs' operations and business parameters.

To create the baseline models, the Rockwell Automation team sampled the flow of pigs through the system for several weeks, tracking them by age. They also looked at the health status of the sow farms where pigs are born, which affects the quantity of pigs released into the system.

Arena's simulations matched flow size to site size and type, maintained that weaning pigs, for example, weren't sent to farms with large pens intended for finishing.

Other variables for the early models included the costs of different facilities, known as yardage costs, as well as facility capacity and annual feed costs. Feed costs were based on projected demand according to the size and age of pigs, and the nearest feed mill.

And because pigs from different sources can introduce new diseases, the project team also designed the models to identify and track the movements of common groups from one location to another.

In the midst of the build-out, The Maschhoffs issued a new challenge to the implementation team: They moved the final implementation date up by several months. The new target date reflected the growing urgency around the reorganization initiative and the need for a modeled regional analysis.

Results

The Rockwell Automation team met the accelerated deadline. The result? Regional modeling and analysis pointed to four management regions, balancing efficiencies in flow, transportation and feed costs with the utilization of contracted sites.

“It was exactly what we needed,” said Dugan. “The data allowed us to make timely recommendations on our new regions.”

After the first modeling phase was complete, the team made additional enhancements: loading live data and transforming the strategic application into a powerful operational decision tool.

“Going forward, we can use the Arena software to manage flow and capacity more efficiently, and give us the flexibility we need to adapt to changing site needs,” Dugan said.

The project team created a real-world model by taking digital “snapshot” of the operation's existing number and ages of pigs and their locations, inputting the data into tables. By repopulating the system with current data, The Maschhoffs can now run the model forward to see occupancy rates or various sites and flows – on a weekly basis, instead of annually, as in the past.

Now the operation can make timely business decisions based on a real-world model that reflects all the variability in their system, clearly visualizing systemic effects of changes.

The Maschhoffs' leadership is confident in the decision-making behind their new regional structure. They also envision many opportunities to forecast future demands using Arena to drive better asset decisions.

 

The results mentioned above are specific to The Maschhoffs' use of Rockwell Automation products and services in conjunction with other products. Specific results may vary for other customers.

 

Trademark Information:

Arena and Rockwell Automation are trademarks of Rockwell Automation, Inc.

Published 02 May 2016

Subscribe

Subscribe to Rockwell Automation and receive the latest news, thought leadership and information directly to your inbox.

Subscribe

Recommended For You

Loading
  • Technical Question
  • Chat Technical Support
  • Phone Support
  • Contact Sales
  • General Questions
  1. Chevron LeftChevron Left Home Chevron RightChevron Right
  2. Chevron LeftChevron Left Company Chevron RightChevron Right
  3. Chevron LeftChevron Left News Chevron RightChevron Right
  4. Chevron LeftChevron Left Case Studies Chevron RightChevron Right
Discover
  • The Connected Enterprise®
  • Create Your Account
  • Case Studies
  • Events
Information for...
  • Distributors
  • OEM
  • System Integrators
  • Encompass Partners
  • Investors
  • Career Seekers
Contact Us
  • General Questions
  • Technical Questions
  • Local Sales & Service
  • Pricing & Availability
  • Report Ethical Concerns
Site Information
  • Legal
  • Privacy Policy
  • Cookie Preferences
  • Terms of Use
  • Trademarks
Change Country Site SelectionChange RockwellAutomation.com site selection to a different country, region or language Change Country
South Africa/English

Keep Updated With Us

Sign up to receive our latest headlines for free.

Stay Informed Now
Follow Us
BlogRockwell Automation's Blog
Copyright ©2021 Rockwell Automation, Inc.
Home