Improvement of New Products for Export to Japan & Sample Prototyping Guidance

Fujicco Co., Ltd. (Indonesia)

Industry: Processed paste products manufacturing / Multi-product line including Kamaboko and fried foods

Challenge:

Declining Yield on Existing Lines
On existing equipment producing multiple products in parallel, yield and quality variability occurred for each product
Lack of Process Standards per Line
Process parameters for each product—mixing time/temperature, cutting and frying conditions—were not defined, leading to operator-dependent procedures
Insufficient Know-how for New Product Development Planning
No established framework for proposing seasoning/form and evaluating prototypes based on market research

Industry

Processed paste products manufacturing / Multi-product line including Kamaboko and fried foods

Challenge

Declining Yield on Existing Lines
On existing equipment producing multiple products in parallel, yield and quality variability occurred for each product
Lack of Process Standards per Line
Process parameters for each product—mixing time/temperature, cutting and frying conditions—were not defined, leading to operator-dependent procedures
Insufficient Know-how for New Product Development Planning
No established framework for proposing seasoning/form and evaluating prototypes based on market research

Solutions

Yield Visualization and Bottleneck Analysis
Collected and analyzed data from raw material input to packaging to identify bottleneck steps for each product
Process Standardization Guidance
Defined optimal conditions and created SOPs for mixing (temperature/time), cutter stopper settings, and frying oil temperature/time by product category
New Product Concept Proposals
Based on Southeast Asian market trends, presented three seasoning/form ideas and designed the prototype evaluation flow
Onsite Training and Knowledge Transfer
Conducted hands-on training per SOPs and helped implement process control checklists and monthly review meetings

Results

Overall yield on existing lines improved

Profile

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