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					1
Performing Traceability for a Food
 Retailer’s Manufactured Products
            Jane Griffith
              October 2006
                             Agenda

Wawa Overview
– Corporate
– Stores
Traceability Strategy
–   Quality Chain
–   Traceability rationale
–   Wawa Strategic Plan
–   QA Strategic Plan
Wawa Traceability Process
AS/RS Overview
– AS/RS Statistics
– Performance Measurements
– Benefits
                                3
Corporate Headquarters




                  4
                             Wawa Market Area



550 stores in 5 states
 – Pa., NJ, Del., Md., Va.
Corporately owned stores
$5 Billion in sales
$2 Billion in Foodservice
sales
26 M Gals. Dairy/year
13 M Gals. Beverage/year
Retail and wholesale
products


                                        5
Super Store – Dover, DE




                    6
Express Case Offer




               7
Deli/Food Service Area




                   8
Hot Entrees and Soups




                   9
Coffee Area




        10
Cold Beverage Display




                        11
12
                                                   Traceability Rationale


Importance of Traceability
– Ensures product safety, and authenticity
    •   During product transportation and distribution
    •   Farm versus wild
    •   Product origin – COOL
    •   Raw ingredient quality
– Legal food safety requirements – National and International
– Additional protection for the global food products and
  source
– Provides Brand Protection
– Reinforces Consumer Confidence in the Brand



                                                                     13
                                                         Wawa Strategic Plan
Product quality and food safety is a cornerstone for what we
        stand for and why we exist, and enables us
    “to be the retail brand our customers can’t live without”.
                                     What We
                                     Stand For


                                    Value People
                                  Delight Customers
                                   Embrace Change
                                  Do the Right Thing
                Where We           Do Things Right       Why We
                Are Going        Passion for Winning      Exist




                   To be the Retail Brand          To Simply
                   Customers Can’t Live          our Customers
                          Without                  Daily Lives




                                                                        14
                                         QA Vision, Mission

 QA’s Vision is to position Wawa as a leader in food
         safety, and brand product quality


Vision:
Wawa will be the marketplace leader in product quality,
 consistency, and food safety

Mission:
To protect the Wawa brand by having quality standards
 and safe food handling practices embraced throughout
 the organization




                                                          15
                                              QA Strategic Plan

  Enhance Traceability by providing quick identification of
product origin from farm to retail using emerging technology.
Traceability is a Critical component of Wawa’s Total Quality
                        System Approach

                   Brand Protection Value
Tracing the origin of a product or its ingredients:
 – Increases product and food safety through accountability
 – Reduces recall costs through quick identification of
   individual lots
Increases consumer brand equity and confidence, by:
 – Ensuring food safety and quality
 – Supports quick, accurate targeted withdrawal of unsafe
   products
                                                              16
Wawa Beverage Center




                17
Wawa Beverage Company




                18
                                         Wawa Beverage Company


The dairy manufacturers 720,000 gallons product
 every week. Wawa Dairy supplies over 550
 stores, and 1000 wholesale customers.

  80 SKUs produced with
   – 60%     -Dairy
   – 40%     -Beverage – Juice and Teas
  8 to 10 SKUs added yearly
  Wawa dairy still prescribed by physicians



                                                           19
                                              Incoming ingredient Screen




At delivery of raw ingredients, load identifier information, seal numbers,
     and microbial results are logged into the computers database.

 Information is added by both the dairy receiver (supplier information)
                  and the lab (tanker initial test results)

                                                                     20
                                         Production Batch Sheet

  Production batch sheets manually record raw ingredient
    lot codes for fluid dairy, beverages, juices, and teas.
Products are traced through production using lot codes and
      information is entered into an Access database




                                                              21
Beverage Filling Room




              22
                   AS/RS Inbound Receiving Process



Beverage fillers
apply bar code
to dairy case
Cases are
stacked 6 high
Moved into
AS/RS via
conveyors
Stacks are
destacked



                                               23
                                AS/RS Inbound Receiving Process


Case Identification
 – 2” Bar code applied by
   Ohio Equipment
   machine in Dairy
 – Product ID
 – Julian date of manufacture
 – Code Date
 – Lot code
Tracking
 – Multiple scanners
   throughout the AS/RS


                                                            24
                                AS/RS Inbound Receiving Process



Storage location is assigned
based on bar code
Variety of product types and
codes within same aisle
Single cases are grouped into
8-case single file groups
SRM picks-up 4 cases per
arm and places in assigned
location




                                                            25
                           Merchandise Flow Control Room
    Merchandise Flow Coordinator monitors store orders


Insure inventory levels
meet order needs
Complete Route leveling
and overloads
Schedule AS/RS product
picks based on route
dispatch times
Merchandise Flow
Coordinator oversees the
process and makes needed
adjustments

                                                     26
                                    Outbound Shipping Process

           After order verification is completed

Orders are released to AS/RS
for picking
SRMs pick products from all 16
aisles
All 16 SRMs work
simultaneously and queue an
order on the outbound
beverage conveyor
Products are picked based on
code date and FIFO



                                                          27
                              Outbound Shipping Process

Each case in the completed order passes the outbound
                  Bar Code Reader

   Updates store invoice
   Ensures accuracy and
   traceability
   Verifies order for
   accuracy and
   completeness
   Approves and releases
   order for loading



                                                    28
29
                                  Store - Wholesale Receiving Process



Delivery Enhancement

   – Inkjet Store number on
     each case
   – Separates store deliveries
     within each route
   – Improves delivery
     accuracy and check-in
     efficiency




                                                                  30
                                              AS/RS Statistics

Beverage Automatic Storage and Retrieval System (AS/RS)
 Development of proprietary Material Handling Control System
  – Hybrid of warehouse management and control systems
 Flexibility to pick cases and single units
 Swisslog AS/RS
  – Began Operation in 2000
  – On-site support
      • Tech Operations Manager
      • Database Engineer
      • Controls Engineer
  – Maintain and troubleshoot PLCs
  – Repairs and PM

                                                           31
                                           AS/RS Statistics

Beverage Automatic Storage and Retrieval System (AS/RS)

AS/RS Dimensions
 – Four stories
 – 80,000 square ft.
 – 16 cranes
    • 2 forks per crane
    • Each holds up to 4 cases per fork
 – 16 Aisles
    • Each with 24 bays and 27 levels
    • Access from 2 sides
 – Capacity to hold 82,000 milk crates

                                                        32
                                                AS/RS Statistics


Beverage Automatic Storage and Retrieval System (AS/RS)

Throughput capability:
 – Inbound – 60 cases per minute
 – Outbound – 45 cases per minute
 – Daily case load – 40,000 cases
 – Product turn rate – 2
 – Retrievable rate – Identification in less than 1 minute
 – Dynamic inventory – amount of available products for
   shipment
 – Ability to place products on immediate M-Hold which
   minimize risk and reduces product withdrawals

                                                             33
                                  Performance Measurements

AS/RS database provides performance matrix to monitor
    daily performance and areas for improvement




                                                        34
                                                                 Benefits

Beverage Automatic Storage and Retrieval System (AS/RS)
Additional Benefits:
 – Safety
     • Reduced manual stacking and assembling of orders
     • Automatic wheel chock lock loading docks
 – Cleanliness:
     • Conveyors are 10 inches off the floor for easy cleaning
 – Quality:
     • Material Holding Capability
     • Dedicated egg storage on bottom of racks
     • 38degrees constant
 – Labor Reduction
     • Automated picking reduced labor costs
 – Improved efficiency and pick accuracy
     • 99.98%


                                                                      35
Thank you for your attention




   jane.m.griffith@wawa.com
       www.mywawa.com

				
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