FISHO (Cod Sheet) Manufacturing Site Yield Improvement
THAI UNION CO., LTD.
Industry: Marine Processing Industry / Surimi Products (Cod Sheet) Manufacturing
Challenge:
Large yield variability and frequent out-of-spec products across all 13 steps from raw material mixing to final packaging.
Aging of the forming drum causing unstable sheet thickness and uneven weight after drying.
Width inconsistency and frequent cutting defects due to stopper misalignment on the guillotine‐style cutter.
Insufficient cooling time before the next process, preventing moisture equilibrium and causing uneven sheet finish.
Industry
Marine Processing Industry / Surimi Products (Cod Sheet) Manufacturing
Challenge
Large yield variability and frequent out-of-spec products across all 13 steps from raw material mixing to final packaging.
Aging of the forming drum causing unstable sheet thickness and uneven weight after drying.
Width inconsistency and frequent cutting defects due to stopper misalignment on the guillotine‐style cutter.
Insufficient cooling time before the next process, preventing moisture equilibrium and causing uneven sheet finish.
Solutions
Visualization of Process Standards
Reviewed and standardized manufacturing conditions (temperature, time, speed, etc.) for all 13 steps and created a process‐standards table.
Data Collection & Anomaly Detection
Quantitatively measured and recorded actual temperature, humidity, weight, etc., at each step and extracted bottlenecks and root causes from out-of-spec data.
Investment Decision Support for Forming Machines
Determined that replacing parts on the aging drum would not yield improvements and delivered an analysis report to justify introducing a new forming machine.
Review of Cutting Method
Evaluated a belt‐type cutter as an alternative to the guillotine style and proposed new equipment to improve cutting precision.
Extension of Cooling Time
Changed from immediate transfer after roasting to a 24-hour cooling period to balance moisture between the air and the sheet, stabilizing yield.
Results
Out-of-spec rate due to thickness variation reduced from ~50% to below 10%.
Cutting defects decreased by 75% compared to before.
Yield improved by an average of 5 percentage points after revising the cooling process.
Process standardization and data visualization enabled monthly quality reviews and established a prevention system for recurrence.
Profile
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