Existing Line Improvement & New Product Development Proposal

Fujicco Co., Ltd. (Indonesia)

Industry: Processed surimi products manufacturing / Multi-product line (crab sticks, fried items)
Challenge:
  1. Declining yield on the existing line
    Parallel production of multiple products on the same equipment led to product-specific yield drops and quality variability.
  2. Lack of process standards for each line
    No clear parameters for mixing time/temperature, cutting/frying conditions, etc., resulting in operator-dependent performance.
  3. Insufficient know-how for new product development planning
    No established framework for proposing flavors/shapes based on market research or for prototype evaluation processes.

Industry

Processed surimi products manufacturing / Multi-product line (crab sticks, fried items)

Challenge

  1. Declining yield on the existing line
    Parallel production of multiple products on the same equipment led to product-specific yield drops and quality variability.
  2. Lack of process standards for each line
    No clear parameters for mixing time/temperature, cutting/frying conditions, etc., resulting in operator-dependent performance.
  3. Insufficient know-how for new product development planning
    No established framework for proposing flavors/shapes based on market research or for prototype evaluation processes.

Solutions

  1. Yield visualization & bottleneck analysis
    Collected and analyzed data for each step from raw material input to packaging, identifying bottleneck processes per product.
  2. Process standardization guidance
    Defined optimal mixing (temperature & time), cutter-stopper settings, frying oil temperature & duration by product category and created SOPs.
  3. New product concept proposals
    Based on trend research in major Southeast Asian markets, presented three seasoning & shape concepts and designed the prototype evaluation flow.
  4. On-site training & knowledge transfer
    Delivered hands-on training using the standardized procedures, and helped implement process-control checklists and monthly review meetings.

Results

  • Achieved an average yield improvement of approximately 7% across the existing line
  • Daily/weekly quality assessments became possible through process standardization, significantly reducing defect recurrence
  • First prototypes of the proposed new products scored 7/10 in client evaluations, advancing to mass-production consideration

Profile

Let’s make your fishcakes unforgettable.

Reach out and discover what tradition and innovation can do for you.
Contact us today!

Contact us

Ready to Put Japanese Surimi Expertise to Work for Your Business? Let’s discuss how we can optimize your fishcake production and drive growth together.

Other Cases

Here are some related cases.
Fujicco Co., Ltd. (Indonesia)
Processed paste products manufacturing / Multi-product line including Kamaboko and fried foods
Fujicco Co., Ltd. (Indonesia)
Processed surimi products manufacturing / Multi-product line (crab sticks, fried items)
Golden Deli Co., Ltd. (Malaysia)
Processed surimi products manufacturing / Fish ball production
VINH HOAN (Vietnam)
Processed surimi products manufacturing / Crab-flavored kamaboko and crab-flavored stick production
OKUHARA FOODS INC. (Hawaii, USA)
Kneading product processing industry/Kamaboko, chikuwa, and deep-fried foods
LUCKY FOODS Co., LTD. (Thailand)
Processed surimi products manufacturing / Fried products (Nigiri-Ten, Maru-Ten)

Want to Learn More?

Dive deeper into the details that matter before implementation: