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Blast Freezer Optimization: Maximizing Throughput in Poultry Cold Chain Management
Project Description
This project addresses the operational challenges faced by Interchange Group, Inc., a third-party logistics company in Harrisonburg, Virginia, in optimizing their blast freezer operations for poultry products. The company aims to increase throughput of Virginia-processed meat while maintaining quality standards and operational efficiency.
Outcomes
A decision support tool to guide pallet placement for arriving trucksA schedule for loading and unloading pallets to maximize throughputAnalysis of maximum monthly capacity and potential excess capacityRecommendations to improve facility utilization toward target metrics (70-80% in process)Performance metrics to evaluate operational efficiencySensitivity analysis to help prepare for varying product mixes and demand scenariosThis project combines prescriptive analytics techniques with practical operational requirements to create an implementable solution that can meaningfully increase the processing capacity of Virginia-sourced poultry products.
Problem Statement :
Interchange Group operates a blast freezer facility with 288 cells arranged in 12 zones of 24 cells each. The company faces several operational challenges:Varying freezing times (22-72 hours) for different poultry SKUsUnpredictable truck arrivals and product mixLimited visibility into upcoming inventorySuboptimal utilization rates (currently operating at 35-40% in-process versus a goal of 70-80%)Need for a systematic approach to pallet placement and retrieval