Production Processes

Mixing and Shortmixing

1. Reviews: Operation of the mixing system.

 Job description, critical task procedures and protective equipment.
 Product Integrity Manual for mixing.
 Mixing Certification
2. Reviews: Product Integrity Manual sections on mixing, short mix, drug usage,
yield reconciliation and formula control.
 Review your regions specific guidelines for formula control and the formula
approval process.
3. Inventory of drugs and premixes:
 Shadow this process to develop an understanding of the correct procedures.
Once competent in this area the associate should be responsible for taking
drug and premix inventories while working in the mixing area (see the training
program timeline for duration).
 The associate should also shadow the drug trax process. Once they have
developed a good understanding of the system, it’s reports, and how to use it
they should begin completing daily drug trax’s inputs.
4. Mixing unit capacities
 Determines the capacities of all conveyors, scales, mixers, legs, spouts, and
scalpers as well as total unit capacity (TPH).
 Understand the flow rates on each feeder screw. Conduct time studies to
ensure that weighing time does not exceed mixing time, creating a bottleneck.
 Determine the capacity of all liquid addition systems.
 Determine mixer RPM.
 Identify two restrictions that would prevent achieving 10 batches/hour.
5. The associate should conduct a time study and compare it to the location’s
model mill standard. After this data has been collected the associate should
analysis it and make a recommendation for improvement.
6. The associate should shadow the person responsible for creating the production
schedule. The associate needs to be able to successfully complete / demonstrate
all of the following:
 How to create a production schedule based on date and time
 How to check current finished feed and ingredient inventories
 How to print arrival tickets
 How to receive arrivals
 How to run transaction log reports (Screen 26 in the logistics menu)
 Understand and successfully complete the 5 musts of LRT daily
7. The associate should review the locations hydration guidelines and the PI
manual section on hydration.
 Why are feeds hydrated?
 What is the max added hydration level for your location?
 How is the hydration added?
  How / where is it metered?
 How is the metering system calibrated?
 How can hydration become an ethical issue?
8. The associate should perform a mixer efficiency test.
9. On-the-job experience: Perform all jobs associated with this area without
supervision and prepare a flow diagram. The associate should be able to
demonstrate how to operate the entire mixing system without any outside
influence. This includes input of formulation, formulation changes, and all
associated record keeping
10. The associate should review and critique process improvement sheets for all
shifts while working in the mixing area.
11. Calculate direct mixing cost/ton, using Model Mill.
12. Reports at least one near miss in a high risk area of mixing and complete
investigation accordingly.
13. The associate reviews tolerances for accuracy and productivity. The associate
should understand and be able to change panel ingredient tolerances, weight
times, etc.
14. Complete Mixing Certification Program.
15. Reference the CAN Plant Operations Talent Development Competencies for
relevant details.
16. Reference World Class Management Model for relevant Accountability and
Competency Statements.
17. Refer to relevant Model Mill process screens and reports.
18. Understand related LRT screens and functions.
19. Reviews and signs off on all related SOP’s for this area.

Formal review with plant manager upon completion of training.

The above questions should be answered on a separate sheet and reviewed with the
plant manager. If something is found to be incorrect or vague the associate should
revisit the area and schedule a second follow up with the PM