Smart tech firm Sauce has launched an innovative solution to enhance operational efficiency for one of the world’s biggest food and beverage companies.
The digital platforms developed by the Hull-based team are aimed at solving complex yard management challenges for confectionery and beverage manufacturer Nestlé.
Now a unique system is being used to track and manage all trailer movements at the firm’s York factory, he home of Nestlé’s 海角视频 confectionery business, where products such as KitKat and Yorkie are manufactured; and at its regional distribution centre, from where batches of Nescafé and Smarties are dispatched.
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The multilingual system could now be rolled out to other Nestlé operations internationally – with the business operates more than 400 factories in over 80 countries.
Sauce chief executive Matt Weldon said: “To have a company the size of Nestlé put their trust in us to deliver this system is huge for us and we are incredibly proud to work with them.
“They have an amazing logistics operation and we’re delighted that we have been able to provide a further digital dimension to it. We have been able to provide Nestlé with the enhanced level of visibility they wanted as part of scalable solution that can be applied to any of their sites.
“Nestlé had looked at various off-the-shelf shelf yard management systems, but none suited their requirements. That’s where we came in. We worked closely with Nestlé to understand exactly what they needed and to create a completely bespoke solution.”
Sauce has created five programmes to meet Nestlé’s requirements – a booking system; a traffic management system; a warehouse tracking system; a shunter tablet app; and a live flight board – which work seamlessly together.
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The system can be accessed in 16 different languages, with contract drivers of many different nationalities visiting the York site daily, and more can be added as required.
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“We have effectively created a suite of applications which can be turned on or off as necessary, based on the particular needs of a given factory or warehouse,” said Sauce lead developer Joe Axon.
“The system has evolved over time as we have developed the software, using our agile methodology. A key point is that, throughout the process, we have worked really closely with Nestlé, and will continue to do so, to ensure the technology we create meets their needs exactly.”
Founded by three friends just four years ago, Sauce has grown rapidly to become an award-winning team of 30, who are currently working seamlessly from home as they continue to support clients through the coronavirus crisis. They are usually based at the Centre for Digital Innovation (C4DI) tech hub, and other major clients include Ideal Boilers and Siemens Gamesa.
Following its launch, the system will now be implemented by Nestlé - which has just signed a major green energy deal to take electricity from Orsted in the Humber - and its strategic logistics partner, XPO Logistics, at the pioneering Digital Distribution Operation of the Future, set to open next month.
The facility, at the East Midlands Gateway development near Castle Donington in Leicestershire, is billed as one of the most advanced buildings of its kind in the world, with its digital ecosystem integrating predictive data and robotics.
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Sauce was approached by Nestlé to develop a bespoke system, with around 500 trailers leaving the site every week, transporting goods to major supermarket chains.
Previously, lorry drivers would drop their trailer off at the warehouse to be unloaded, then remain in a waiting area until it was ready, or collect a previously loaded trailer.
Communication was via two-way radio or walkie talkies and the recording system was largely paper-based.
Now drivers input details digitally upon arrival at security, including their name, vehicle and trailer numbers. They then wait in a designated area where they can view a “flight board” – similar to an airport or train station information screen – enabling them to monitor the status of their load. When it has been loaded or unloaded, they can return to their vehicle and leave the site.
Shunter drivers, who manoeuvre delivery trailers on and off-loading bays at the warehouse and factories, also access the live information via a tablet in their cab, meaning they are fully aware of all movements on site.
David Walker, Nestlé’s logistics transformation projects manager added: "The Sauce team's approach has been fantastic and they have been really easy to work with.
"They have built a bespoke solution from scratch to tackle the challenges we faced and it is in operation within 12 months of our first discussion, which we think is incredible."
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Chris Pickles, delivery operations manager at Nestlé’s York centre, which operates 24/7 for 364 days of the year, said: “This site is one of the most complex of Nestlé’s operations because we have both factory and warehouse functions on the same site – usually it is one or the other.
“This will solve key issues for the York site, which means it will also work for other operations. If any other Nestlé factory or warehouse wants an advanced, digital yard management system, we now have it and can configure it to their requirements within days.”