Jerome Cheese Case Study

Factory-Wide Automation Stabilisation & Lean Transformation

Jerome Cheese (Davisco Foods) | Idaho, USA

Role: Automation / Improvement Engineer
Sector: High-Volume Food Manufacturing
Project Type: Operational Stabilisation & Waste Elimination

1. Executive Overview

Jerome Cheese is a high-output cheese production facility operating complex palletising robots, barrel handling systems, vacuum sealing equipment, and automated conveyor networks.

Although initially hired as an Automation / Electrical Engineer, the operational instability across multiple systems required a broader engineering intervention. I was tasked with functioning as an Improvement Engineer, leading factory-wide root cause elimination, lean optimisation, and structural reliability improvements.

The objective was clear:

Move the operation from reactive firefighting to engineered stability and predictable output.

2. Operational Challenges

The factory was experiencing:

  • Recurring robotic instability
  • Tons of daily product loss
  • Barrel tipping and elevator overloading
  • Conveyor jams and mechanical complexity
  • Main drive trip-outs
  • Unreliable vacuum sealing start-up
  • No structured preventative maintenance systems
  • Continuous need for operator supervision in unstable areas

These issues were systemic rather than isolated.

3. Strategic Engineering Approach

The intervention was structured around:

  • Deep root cause analysis at PLC and mechanical levels
  • Lean simplification (removing failure points rather than repairing them)
  • Control logic optimisation
  • Mechanical redesign where required
  • Predictive risk identification
  • Structured preventative maintenance architecture
  • Direct reporting to Engineering Manager with cross-team collaboration

The focus was permanent elimination — not temporary repair.

4. Technical Interventions

4.1 Robotic Systems Stabilisation

Okura Columbia Models 700, 1555 & 1600

  • Advanced programming and fault diagnostics
  • Elimination of box slipping from robot palms
  • Identification of T-axis reducer and servo degradation risks
  • Led servo motor replacement and encoder re-zeroing
  • Full recommissioning to operational precision

Outcome:
Unexpected robotic downtime events were completely eradicated, restoring predictable palletising performance.

4.2 Elimination of Recurring Cheese Waste

Through PLC restructuring, additional interlocks, mechanical adjustments and process optimisation:

  • Daily recurring product loss was eliminated
  • Barrel mis-sequencing corrected
  • Product misalignment removed
  • Flow instability resolved

This stopped the repeated loss of tons of cheese that had previously been considered unavoidable.

4.3 Barrel Room System Re-Engineering

Recurring failures included:

  • Barrels falling from turntables
  • Dual-barrel elevator entry
  • Poor spacing and centring
  • Scanner read failures
  • Requirement for constant operator supervision

By redesigning control logic and improving mechanical sequencing:

  • Barrel tipping risk eliminated
  • Double entry into elevators eliminated
  • Gap control stabilised
  • Scanner reliability restored
  • Manual supervision removed

A previously unstable high-loss area became a controlled process.

4.4 Lean Conveyor Redesign

In the boxing area, repeated jams were caused by an overcomplicated changeover ram system.

Solution:

  • Implemented a 30° angled activated belt
  • Removed the changeover ram entirely

Impact:

  • Jam conditions eliminated
  • High-maintenance component removed
  • Reduced downtime
  • Simplified mechanical architecture

The same design approach eliminated unjustified box rejection in the Mozzarella room.

4.5 Main Drive & Critical Fault Elimination

  • Identified root cause of recurring main drive trip
  • Restored stable operation
  • Eliminated backlog conditions

4.6 Betavac & Mozzarella Robot Stabilisation

  • Eliminated shift-start instability in vacuum sealing system
  • Diagnosed and corrected unexplained mid-cycle robot stoppages

5. Preventative Maintenance & System Sustainability

At engagement, critical systems lacked structured PM regimes.

I developed and implemented comprehensive preventative maintenance frameworks for:

  • 3 palletising robots
  • 2 pallet & sheet dispensers
  • 3 stretch wrapping machines
  • Conveyors, elevators, turntables

Each PM included:

  • Detailed task instructions
  • Correct greasing procedures
  • Failure point inspection criteria
  • Structured service intervals

This transitioned the site from reactive maintenance to sustainable reliability engineering.

6. Leadership & Cross-Functional Contribution

  • Reported directly to Engineering Manager
  • Coordinated with automation and maintenance teams
  • Managed subcontractor integration
  • Commissioned new installations (ifm AS-i gateways, sensors, Tuchenhagen valves)
  • Authored technical manuals
  • Trained engineering and production staff
  • Presented costed improvement proposals for long-term redesign

Several strategic upgrades were documented for future implementation beyond my tenure.

7. Measurable Operational Impact

  • Recurring robotic downtime eradicated
  • Daily cheese waste eliminated
  • Barrel room instability eliminated
  • Conveyor jam conditions removed
  • Main drive trip events eliminated
  • Operator supervision requirement reduced
  • Lean process stability introduced
  • Preventative maintenance architecture implemented

8. Key Capabilities Demonstrated

  • Advanced PLC optimisation
  • Industrial robotic stabilisation
  • Lean manufacturing transformation
  • Root cause elimination
  • Mechanical simplification engineering
  • Preventative maintenance system architecture
  • Commissioning & automation integration
  • Operational risk mitigation
  • Board-level technical communication
Tweet
Share
Share
Pin
0 Shares