Efficient Remote Monitoring and Efficient Remote Monitoring and Efficient Remote Monitoring and Efficient Remote Monitoring and Control of Food and Pharmaceutical Control of Food and Pharmaceutical Safety and Preventing Maintenance Safety and Preventing Maintenance

System System

Gideon Zeidler D.SC/MBAGideon Zeidler D.SC/MBAf Sf S CCDepartment of Animal Science Department of Animal Science ––CooperativeCooperative

Extension, University of California, RiversideExtension, University of California, RiversideCalifornia, United States of AmericaCalifornia, United States of America

Presented AtPresented At44thth International Workshop “Cold Chain Management” International Workshop “Cold Chain Management” 44thth International Workshop “Cold Chain Management” International Workshop “Cold Chain Management”

September 27September 27thth --2828thth 20102010University of Bonn University of Bonn –– City of Bonn, GermanyCity of Bonn, Germany

This Project was Conducted in This Project was Conducted in jjCooperation BetweenCooperation Between

EE--Control SystemsControl SystemsyyChatsworth, CaliforniaChatsworth, California

AndAndAndAnd

The University of CaliforniaThe University of CaliforniaRiverside CaliforniaRiverside CaliforniaRiverside, CaliforniaRiverside, California

IntroductionIntroduction

The objective of this project was toThe objective of this project was to The objective of this project was to The objective of this project was to transform Food Safety (HACCP) System transform Food Safety (HACCP) System from reactive to profrom reactive to pro active system Toactive system Tofrom reactive to profrom reactive to pro--active system. To active system. To improve its performances and efficiency, improve its performances and efficiency, significantly reduce its cost and to expand significantly reduce its cost and to expand managerial decision capabilities and managerial decision capabilities and g pg psupervision using a unique combination of supervision using a unique combination of wireless the internet and the newlywireless the internet and the newlywireless, the internet and the newly wireless, the internet and the newly developed electronic management tools developed electronic management tools system (MTS)system (MTS)system (MTS).system (MTS).

The First Breakthrough in 1989. The First Breakthrough in 1989. Using the GPS to Remote MonitorUsing the GPS to Remote MonitorUsing the GPS to Remote Monitor Using the GPS to Remote Monitor

TransTrans--Oceanic Chilled Meat Oceanic Chilled Meat Transport Transport (New Zealand to California and to Hamburg)(New Zealand to California and to Hamburg)

The Economist Prediction on the upcomingThe Economist Prediction on the upcomingf ( )f ( )of the Wireless Revolution (2007)of the Wireless Revolution (2007)

Ti RF R di ill i f b iTi RF R di ill i f b iTiny RF Radios will inform us on many business Tiny RF Radios will inform us on many business and personal interestsand personal interests

Business Week Prediction on Expanding of Business Week Prediction on Expanding of M i l E ti d S i i iM i l E ti d S i i iManagerial Expertise and Supervision using Managerial Expertise and Supervision using

Wireless TechnologyWireless Technology (2007)(2007)( )( )

Primary Requirements From Primary Requirements From Effective Monitoring SystemEffective Monitoring SystemEffective Monitoring SystemEffective Monitoring System

Continuous Monitoring: To allow statistical process Continuous Monitoring: To allow statistical process control (SPC) (not possible in spot checking)control (SPC) (not possible in spot checking)

Sensor Monitoring: Including, time and countingSensor Monitoring: Including, time and counting Sensor Monitoring: Including, time and counting Sensor Monitoring: Including, time and counting machine monitoring machine monitoring

Automated Monitoring: Minimize humanAutomated Monitoring: Minimize human Automated Monitoring: Minimize human Automated Monitoring: Minimize human involvement and human errorsinvolvement and human errors

Fast Response: Rapid Problem identification and Fast Response: Rapid Problem identification and solving, maximized by: Electronic Management solving, maximized by: Electronic Management ToolsTools

The Secondary Requirements The Secondary Requirements From Monitoring SystemsFrom Monitoring Systems

Wireless SystemWireless SystemWireless SystemWireless System

Remote Monitoring SystemRemote Monitoring Systemg yg y

High Level Security SystemHigh Level Security SystemIn Order To Prevent System In Order To Prevent System Abuse. (Food Security) Abuse. (Food Security)

The Secondary Requirements The Secondary Requirements From Monitoring Systems (cont.)From Monitoring Systems (cont.)

Ability To integrate all Processing and Ability To integrate all Processing and accessory equipment in the line into one accessory equipment in the line into one y q py q poperating system operating system

Ability To integrate all Processing Lines Ability To integrate all Processing Lines and Suband Sub--Facilities in that location into one Facilities in that location into one operating system.operating system.operating system.operating system.

Ability To integrate all locations into one Ability To integrate all locations into one operating system regardless of distance.operating system regardless of distance.

Fundamentals: Composition Fundamentals: Composition of the Remote Monitoring Systemsof the Remote Monitoring Systems

It is composed of three major components:It is composed of three major components:

A The Receiver / TransmitterA The Receiver / TransmitterA. The Receiver / TransmitterA. The Receiver / Transmitter

B. The collectorB. The collector

C. The SoftwareC. The Software

Fundamentals:Fundamentals:The Data Acquisition System (DAS)The Data Acquisition System (DAS)The Data Acquisition System (DAS)The Data Acquisition System (DAS)

When one Receiver / When one Receiver / T ittT ittTransmitter, one Transmitter, one collector and one collector and one software are connectedsoftware are connectedsoftware are connected software are connected and programmed and programmed together they createtogether they createtogether they create together they create DAS. Which can DAS. Which can expand without limits.expand without limits.expand without limits. expand without limits. By adding Transmitters By adding Transmitters and Collectors. and Collectors. However, only ONE However, only ONE Software is needed to Software is needed to operate any size operate any size system .system .

Horizontal DAS ExpansionsHorizontal DAS Expansions(In One Location)(In One Location)(In One Location)(In One Location)

Vertical IntegrationVertical IntegrationIntegrating the Operation Systems ofIntegrating the Operation Systems ofIntegrating the Operation Systems of Integrating the Operation Systems of

Multiple LocationsMultiple Locations

Operation of the SystemOperation of the SystemThe SoftwareThe SoftwareThe SoftwareThe Software

Can be placed anywhereCan be placed anywhere

Collect, process, and Store dataCollect, process, and Store data

Issue reports and send them back to the facilities Issue reports and send them back to the facilities and to other designated addressand to other designated addressand to other designated addressand to other designated address

Issue warnings and alarms when specifications areIssue warnings and alarms when specifications are Issue warnings and alarms when specifications are Issue warnings and alarms when specifications are not met not met

Check the system, identifies the problem and issue Check the system, identifies the problem and issue work orders (Preventive Maintenance)work orders (Preventive Maintenance)

Check and approve work done (if appropriate)Check and approve work done (if appropriate)

The Software (cont )The Software (cont )The Software (cont.)The Software (cont.)

The New High Level Security System:The New High Level Security System:

Prevent Industrial Espionage (Stealing FormulationsPrevent Industrial Espionage (Stealing FormulationsProcesses Production Information)Processes Production Information)Processes Production Information)Processes Production Information)

Prevent System Abuse: (Manipulating of formulationPrevent System Abuse: (Manipulating of formulation Prevent System Abuse: (Manipulating of formulationPrevent System Abuse: (Manipulating of formulationand processes.)and processes.)

Preventing Teorisists Actions: (in pharmaceutics Preventing Teorisists Actions: (in pharmaceutics e e g eo s s s c o s ( p a aceu cse e g eo s s s c o s ( p a aceu csincreasing medicine doses can kill people) increasing medicine doses can kill people)

There are Two Available Systems:There are Two Available Systems:There are Two Available Systems: There are Two Available Systems:

The Static Monitoring SystemThe Static Monitoring System

The Portable Monitoring SystemThe Portable Monitoring System The Portable Monitoring SystemThe Portable Monitoring System

The Static Monitoring SystemThe Static Monitoring System

The Advanced Transmitter / Collector is in the shape of electronic board which isthe shape of electronic board which is

integrated into the electronic board of the i tequipment.

Operation of the Portable SystemOperation of the Portable Systemyy

Operation of The Portable SystemOperation of The Portable SystemOperation of The Portable SystemOperation of The Portable System

The Portable System: the The Portable System: the integration of kitchen equipmentintegration of kitchen equipment

San Bernardino Unified SchoolDistrict Central Kitchen (Serving 70 Schools)District Central Kitchen (Serving 70 Schools)

The New Electronic Management The New Electronic Management ggTool System (MTS), WhatTool System (MTS), What

C it d f ?C it d f ?Can it do for us?Can it do for us? Compare Cold Chain Component Compare Cold Chain Component p pp p

PerformancePerformance

Research Tool for Comparing Scientific Research Tool for Comparing Scientific and Technical Treatments.and Technical Treatments.

Better Utilization of Resources (Labor and Better Utilization of Resources (Labor and Raw Materials.Raw Materials.

The New Electronic Management The New Electronic Management ggTool System (MTS), WhatTool System (MTS), WhatCan it do for s? (Cont )Can it do for s? (Cont )

Fast Reaction to Emerging Food SafetyFast Reaction to Emerging Food Safety

Can it do for us? (Cont.)Can it do for us? (Cont.) Fast Reaction to Emerging Food Safety Fast Reaction to Emerging Food Safety

Problems by Connecting Food Safety Problems by Connecting Food Safety Management and Risk AssessmentManagement and Risk AssessmentManagement and Risk Assessment.Management and Risk Assessment.

Protecting Expensive Refrigerated Protecting Expensive Refrigerated Content of Coolers in PharmaceuticsContent of Coolers in PharmaceuticsContent of Coolers in Pharmaceutics Content of Coolers in Pharmaceutics and Research. and Research.

Large Number of New ideas Large Number of New ideas

Elevating The Performance Of TheElevating The Performance Of TheElevating The Performance Of The Elevating The Performance Of The Cold Chain by identified Weak Units Cold Chain by identified Weak Units

i lti it O ti Th hi lti it O ti Th hin multi units Operations Through in multi units Operations Through Performance Comparison. Performance Comparison. pp

Example for Management ToolsExample for Management ToolsO S R tO S R tOne Screen ReportOne Screen Report

..

Management Tools: Summary ofManagement Tools: Summary ofRefrigeration Problems inRefrigeration Problems inRefrigeration Problems in Refrigeration Problems in

Twenty Schools of one unified Twenty Schools of one unified School Systems.School Systems.

Fault Summary ReportsFault Summary ReportsFault Summary ReportsFault Summary Reports

Management Tools Operations Management Tools Operations in a Hospital and its Pharmacy in a Hospital and its Pharmacy

Several Monitoring Points (Out Several Monitoring Points (Out ))of 60) in a Hospital of 60) in a Hospital

SCU Medication Refrigerator Lab Storage Ambient TemperatureSCU Medication Refrigerator

Pharmacy Small Freezer

Pharmacy Refrigerator

g p

Lab Refrigerator

Istotemp Lab Refrigerator

Pharmacy Large Freezer

OB Solution Warmer

OB R f i t Di t

Storage - Room Temperature

Storage - Freezer #2

S F #1OB Refrigerator - Dietary

OB Medication Refrigerator

Night Box Medication Refrigerator

Storage - Freezer #1

Pharmacy Refrigerator - Annex

Kitchen - Sandwich BarNight Box Medication Refrigerator

Med Surg South Refrigerator -Dietary

Med Surg South Medication Refrigerator

Kitchen Sandwich Bar

Kitchen - Salad Refrigerator

Kitchen - Cook RefrigeratorMed Surg South Freezer - Dietary

Med Surg North Refrigerator - Dietary

Med Surg North Medication

g

Freezer Room - R20

Freezer Room - R05Med Surg North Medication

Refrigerator

Med Surg North Freezer - Dietary

Freezer Room - R04

Freezer Room - Ambient Temperature

Better Utilization ofBetter Utilization ofBetter Utilization of Better Utilization of ResourcesResourcesResourcesResources

Case No.1. The Effect of MultiCase No.1. The Effect of Multi--Unit Unit Integration in County Schools FoodIntegration in County Schools FoodIntegration in County Schools Food Integration in County Schools Food

ProgramProgramENTITY: Duncanville School District, Duncanville County, Texas

THE SCHOOL SYSTEM :

about 13,000 students and staff from 23 school district schools and 11 other schools are dinning daily during school daysSYSTEM : dinning daily during school days.

THE FACILITY: 34 school’s kitchens and dinning rooms, meat breaking operations, baker, central kitchen, cold storage and distribution system. Plan to provide HACCP monitoring and supervision to additional 21 schools in the district by integrating them to his system In addition theyto additional 21 schools in the district by integrating them to his system. In addition they provide 800 to 1000 catering events per year to the district as well as 250,000 meals to the USDA summer feeding program.

FEATURES: Automated HACCP monitoring with warning system. Central managing and supervision which can react to instant information in real timewhich can react to instant information in real time.

MAJOR ACHIEVEMENTS:

50% labor cost reduction as production was double with same number of people. 20% food saving as to wasted food, spoiled food and deteriorated food.

DURATION OF

THE PROGRAM:

About 5 years. Duncanville school district was among the

first to Install the system and they are now upgrading its

capabilities.

Case No.2. The Effect of Improving Case No.2. The Effect of Improving Production ControlProduction Control

J k t J ti C i H t l M t Mi t

ENTITY:

Jackpot Junction Casino Hotel, Morton, Minnesota

NUMBER OF GUESTS: ON the average 3,000 to 4,000 per day ,midweek and 14,000 to 15,000 Per day weekends and holidays.

THE FACILITY:

One band new kitchen, and 4 restaurants: cafeteria, full deck grill, fast food And employees restaurant.

EXISTING PROBLEM: the kitchen is not well responding to the fluctuating number of patrons. As a result heavy pressure is inserted on employees to satisfy customers in short time. Despite their effort Manu items are not available upon request while some surplus items are discarded at the end of the day.

NEW FEATURES: Automated HACCP, Preventive maintenance HACCP, Highly automated processing and production control system. The chef can send from his computer to each of the dozens Cooking appliances and cold dishes preparation the recipe, quantities of ingredients, preparation and cooking specifications and number of Manu items expected He adjust the hundreds of Manu itemsInventory with point of sale activity andexpected. He adjust the hundreds of Manu itemsInventory with point of sale activity and the updated information on coming guests.

MAIN ACHIEVEMENTS:

18% labor savings and 10% food saving while doubling production. Better and faster response to fluctuating number of guests during the day.

DURATION OF THE PROGRAM: 9 months

Protecting Expensive content ofProtecting Expensive content ofProtecting Expensive content of Protecting Expensive content of Coolers in Research and Coolers in Research and

PharmaceuticsPharmaceuticsPharmaceutics.Pharmaceutics. Keep Temperature Monitoring Even Keep Temperature Monitoring Even p p gp p g

During Electricity Shut down or Equipment During Electricity Shut down or Equipment Brake down.Brake down.

Instantly Identify the Unit and its Problems Instantly Identify the Unit and its Problems and Recommend Correction Actionand Recommend Correction Actionand Recommend Correction Action. and Recommend Correction Action. (In a large Institution there are Hundreds (In a large Institution there are Hundreds of Units)of Units)of Units)of Units)

Work in ProgressWork in ProgressWork in ProgressWork in ProgressMonitoring and Control ofMonitoring and Control ofMonitoring and Control of Monitoring and Control of

Emerging Problems: Emerging Problems: g gg gIntegratingIntegrating Risk Management Data (HACCP) with Risk Management Data (HACCP) with Risk Assessment Data Prioritizing Actions andRisk Assessment Data Prioritizing Actions andRisk Assessment Data, Prioritizing Actions and Risk Assessment Data, Prioritizing Actions and Monitory Implications in Real Time, For Rapid Monitory Implications in Real Time, For Rapid Decision MakingDecision MakingggExamples:Examples:-- Undercooked Batch of Chicken Meat Product.Undercooked Batch of Chicken Meat Product.Undercooked Batch of Chicken Meat Product.Undercooked Batch of Chicken Meat Product.-- Truck’s Refrigeration System Broke Down on Truck’s Refrigeration System Broke Down on the Road.the Road.the Road.the Road.

Future WorkFuture WorkFuture WorkFuture Work

The automation of the management tools The automation of the management tools ggsystem system

Integration of Artificial intelligence into Integration of Artificial intelligence into l i h f fl i h f fmanagement tool system in the form of management tool system in the form of

specifically designed Algorithm.specifically designed Algorithm.

The Unmanned Israeli Armored Patrol Vehicle: GardiumCan independently Identify and Destroy Targets UsingCan independently Identify and Destroy Targets Using

Artificial Intelligence.

Potential Risks In Using Potential Risks In Using The Automated SystemThe Automated System

The Wireless System is Wide Open and The Wireless System is Wide Open and Anyone can access it if you know how.Anyone can access it if you know how.

It Can Easily be a Target for Sabotage It Can Easily be a Target for Sabotage and Terrorist Activitiesand Terrorist Activities

In 2008 Airline Crash was associate with In 2008 Airline Crash was associate with Malicious Infections which Shut down the Malicious Infections which Shut down the warning system. The Plane Had Problem warning system. The Plane Had Problem which the Pilots didn’t know.which the Pilots didn’t know.

This Monitoring System has Security This Monitoring System has Security Protection Equal or better then that of the Protection Equal or better then that of the B ki S tB ki S tBanking System.Banking System.

Parameters that contribute to Parameters that contribute to the low cost of the system.the low cost of the system.

Only one software is needed to operate Only one software is needed to operate the system regardless of size. =Low Costthe system regardless of size. =Low Cost

Small capital investment is needed to start Small capital investment is needed to start upfront. Future expansion at will.upfront. Future expansion at will.p pp p

Major Labor (up to 50%) and material (up Major Labor (up to 50%) and material (up to 20%) savings.to 20%) savings.) g) g

Substantial reduction in equipment Substantial reduction in equipment breakdown do to online preventive breakdown do to online preventive ppmaintenance. Low Plant Down Time.maintenance. Low Plant Down Time.

Improved productivity and plant operation Improved productivity and plant operation p p y p pp p y p pefficiency do to improved management efficiency do to improved management supervision.supervision.

Users of the SystemUsers of the SystemUsers of the SystemUsers of the System

O er 5 000 Uni ersities and SchoolsO er 5 000 Uni ersities and Schools Over 5,000 Universities and SchoolsOver 5,000 Universities and Schools Over 750 Hospitals and Care ProvidersOver 750 Hospitals and Care Providers

Restaurants Hotels conventions centersRestaurants Hotels conventions centers Restaurants, Hotels, conventions centersRestaurants, Hotels, conventions centers Supermarket DelisSupermarket Delis

Casinos Correctional Facilities MilitaryCasinos Correctional Facilities Military Casinos, Correctional Facilities, Military Casinos, Correctional Facilities, Military institutions, Parliamentsinstitutions, Parliaments

Meat plants Bakeries Central KitchensMeat plants Bakeries Central Kitchens Meat plants, Bakeries, Central KitchensMeat plants, Bakeries, Central Kitchens Commercial Kitchens ManufacturesCommercial Kitchens Manufactures Cold Storage Warehouses and display casesCold Storage Warehouses and display cases Cold Storage Warehouses and display casesCold Storage Warehouses and display cases Refrigeration Systems ManufacturesRefrigeration Systems Manufactures

Thank YouThank YouFor YourFor YourFor YourFor YourAttentionAttentionAttention Attention