Declining yield on the existing line
Parallel production of multiple products on the same equipment led to product-specific yield drops and quality variability.
Lack of process standards for each line
No clear parameters for mixing time/temperature, cutting/frying conditions, etc., resulting in operator-dependent performance.
Insufficient know-how for new product development planning
No established framework for proposing flavors/shapes based on market research or for prototype evaluation processes.
Declining yield on the existing line
Parallel production of multiple products on the same equipment led to product-specific yield drops and quality variability.
Lack of process standards for each line
No clear parameters for mixing time/temperature, cutting/frying conditions, etc., resulting in operator-dependent performance.
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
Yield visualization & bottleneck analysis
Collected and analyzed data for each step from raw material input to packaging, identifying bottleneck processes per product.
Process standardization guidance
Defined optimal mixing (temperature & time), cutter-stopper settings, frying oil temperature & duration by product category and created SOPs.
New product concept proposals
Based on trend research in major Southeast Asian markets, presented three seasoning & shape concepts and designed the prototype evaluation flow.
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!
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.