WPTEC DTS Production Error-Proofing System: Creating a New Benchmark for Intelligent Production in the Kimchi Industry

Application Case of DTS Production Error-Proofing and Traceability Management System in the Kimchi Industry

Challenges and Opportunities in the Kimchi Industry

As a representative of the traditional food industry, the kimchi sector has recently faced an urgent need for large-scale and standardized production. However, issues such as batching errors, data discontinuities, and raw material waste under the traditional manual management model have severely restricted enterprises' production efficiency and product quality. How to achieve precise control in complex salinization environments while ensuring data traceability has become the key to industrial upgrading.

Industry Pain Points: Four Major Difficulties in Traditional Production Modes

• Frequent manual operation errors: In the batching process, problems such as taking wrong materials, inaccurate weighing, missed/repeated feeding often occur, directly affecting product quality.
• Inefficient data management: Manual recording of production data is error-prone, report preparation is cumbersome, and traceability is difficult, failing to meet modern quality management requirements.
• Uncontrollable raw material loss: With multiple workshops and humid environments, it is hard to implement the "first-in, first-out" principle for raw materials, making it impossible to accurately track losses.
• Insufficient equipment durability: Ordinary equipment is prone to corrosion in salt spray environments, leading to high maintenance costs and affecting production continuity.

Solution: WPTEC DTS-Net Production Error-Proofing and Traceability System

WPTEC DTS system deeply integrates IoT technology and lean production concepts, providing kimchi enterprises with a full-process digital management solution from raw materials to finished products, helping enterprises achieve intelligent production characterized by "zero error, full transparency, and high resilience".

Core Function Highlights

Intelligent Error Prevention and Precise Batching

• Foolproof operation design: Through ISOP graphical process guidance, workers receive real-time operation prompts; incorrect steps trigger automatic alarms and operation blocking, ensuring batching accuracy and feeding specifications.
• Formula review and permission management: Strictly control the permission to modify formulas, prevent manual tampering, and ensure the security of core data.

Full-Process Data Traceability

• Transparent chain from raw materials to finished products: The system collects real-time data from weighing, feeding, packaging and other links, supporting reverse traceability of finished products to raw material batches, suppliers, operators and production time.
• Daily settlement and loss analysis: Automatically generate raw material consumption reports, accurately locate loss links, and help optimize costs.

Efficient Collaboration and Intelligent Scheduling

• Two-level issuance of production plans: Dynamically adjust task priorities according to the inventory of main materials, realizing flexible allocation of workshop-level and production line-level tasks.
• Multi-workshop inventory linkage: Independent accounting and global visual management of temporary storage warehouses in each workshop, ensuring efficient circulation of raw materials and avoiding expiration waste.

Special Equipment for Salt Spray Environment

• Industrial-grade durable design: All 304 stainless steel intelligent instruments with IP69K protection level, resistant to humidity and salt spray corrosion, ensuring long-term stable operation of equipment.

Implementation Effects: Cost Reduction, Efficiency Improvement, and Quality Leap

• Quality improvement: The human error rate has been reduced by more than 90%, and the batching accuracy has reached 99.5%, ensuring that each batch of products meets standards.
• Cost optimization: Raw material loss has been reduced by 30%, equipment maintenance costs have decreased by 50%, and overall efficiency has increased by 40%.
• Management upgrade: Production data is uploaded to the SAP system in real time, allowing management to remotely monitor progress, quickly respond to abnormalities, and improve decision-making efficiency by 60%.

Stepping into a New Era of Kimchi Intelligent Manufacturing