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TSþþ extends TSþ with the addition that the cocoa farmers,when packing the cocoa beans, already mark all bags with uniquecodes and date. In this case the finished chocolate is traceable up tothe individual cocoa farmer. Alternatively, the local buying stationcould mark the bags at arrival, with the information of the farmerdelivering the beans.In Fig. 3 the different traceability systems can be seen.3.3.3. Different product recallsThe simulation model is able to simulate two possible foodcrises and corresponding recalls (R1 and R2) that could occur in thecase study supply chain. R1 simulates the product recall in case ofa contamination of the cocoa beans, which could be a chemicalcontamination while farming, fermenting or drying. In this case allchocolate bars produced with cocoa beans from a certain cocoafarmer need to be recalled. R2 simulates the product recall in caseof a contamination of a processing batch, which could be caused bya problem in a roasting process. In this case all chocolate barsproduced in a certain roasting process need to be recalled. Thesimulation models allow to run single and multiple simulations.Due to the importance of the roasting process it is also possible torun single or multiple simulations automatically for different processingbatch sizes. For this paper, we simulated the food scares fora range of processing batch sizes between 1,600 kg and 5,000 kg(every multiple of 200 kg). Each of the sizes is then run multiple
times, while information such as number of runs, processing batch
size, recall size and number of processing batches (which reflects
the production efficiency) is registered, and average results can be
determined.
4. Results and discussion
4.1. Comparing different production strategies
In order to compare the production strategy based on production
efficiency (PS1) to the production strategy based on reduced
batch dispersion (PS2) the simulation model has been run for
different processing batch sizes. The average results are shown in
Fig. 4 as the difference in percentages between the two production
strategies (values of PS1 represent the 100%) in (i) production
efficiency, (ii) recall size in case of contamination of the raw
materials (R1) and (iii) recall size in case of contamination of
a processing batch size (R2).
PS2 is a production strategy where the batches of raw materials
are not mixed. Thus, the last processing batch from a raw material
batch might not fully occupy the batch processing equipment. That
is, the production equipment that processes this smaller batch will
only be partially utilized. The actual overall utilization therefore
depends on the processing batch size b and the raw materials batch
size n. Combined, these two factors lead to a required number of
processing batches r (with r ¼ n/b) and a utilization of
u ¼ r
QrS
100% (1)
where QrS denotes the smallest integer larger than or equal to r. For
situations in which the processing batch size is fixed (as can be
expected in industry), but raw material batch size varies, this leads
to different expected utilizations for each possible processing batch
size b:
ub ¼ 1
jNjX
i˛N
ri
QriS
(2)
where ri is the required number of batches for raw material batch
size ni, i ˛ N an index representing the different possible raw
material batch sizes used in the simulation (based on the uniform
distribution discussed in Section 2.2), and rNr the number of
elements in set N. The expected process utilization value ub for the
processing batch sizes simulated in our case study when using PS2
can be seen in Fig. 5.
Fig. 5 shows that, by simulating a large number of possible raw
material batch sizes, and thus a large set N, the expected utilization
ub varies significantly. When producing with PS1, the raw material
batches are mixed, always processing with fully occupied batch
processing equipment, thus reaching high utilization in the
production processes. Therefore, the number of processing batches
for PS1, representing production efficiency, has a decreasing trend
for an increasing processing batch size. As the decrease in the
number of processing batches for PS2 is not constant, the
percentage difference between the two production strategies is not
increasing at a constant rate in Fig. 4. This is most visible at processing
batch sizes around 4,400 kg, but smaller incontinuities can
be noticed around 2,800 kg and 3,600 kg. A chocolate manufacturer
that produces with a PS2 production strategy should therefore take
the expected utilization value ub as calculated in (2) and illustrated in Fig. 5 into account when deciding on the size of the processing
batches.
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