GENAU: AI Supported Data Capture and Factory Management for Meat and Food Production

By Eben and Kristi van Tonder

Table of Contents

Introduction

GENAU modernises factory control by combining the speed of a holistic system of manual registers with AI-supported extraction, validation and consolidation. It delivers real-time stock visibility, stable FIFO, improved yields and full traceability without altering existing ERP systems or requiring hardware investment. It is a leading solution for uniting user-generated data with advanced automation in a single, dependable system.

Executive summary

In German, Genau refers to exactness and precision, which reflects the purpose of the system.

Many meat and poultry plants still depend on a holistic system of user-generated registers. These entries are fast and reliable, but seldom form part of a unified operational system. This leads to gaps in stock visibility, yield clarity and traceability.

GENAU introduces a unified numbering logic, standardised registers, AI-supported extraction and a central Master Workbook that mirrors the physical flow of crates and stock. The system produces accurate, live and audit-ready reporting.

Key points

• Real-time visibility across all chillers and freezers
• True FIFO
• Improved yields and reduced shrinkage
• Complete stock traceability
• Stable daily operations
• No ERP changes

Core system and the OSASS philosophy

GENAU is structured around Order, Sanitation, Arrangement, Standardisation and Self-discipline. These form the daily operating logic of a stable plant.

Order: Order creates a manageable environment.
Sanitation: Cleanliness stabilises the environment once order is restored.
Arrangement: Exact zones, flows, and crate logic create predictability.
Standardisation: Correct methods become formal rules, registers and numbering.
Self-discipline: Daily adherence keeps operations stable and transparent.

Standardised Manual Registers

Registers remain the quickest way to capture information on the factory floor. GENAU standardises these registers so all departments record the same fields in the same structure. Physical hard cover registers are fast. GENAU adds precision and consolidation. Deboning registries and processing records complete the picture with detailed yield reports and batch control. Everything is integrated into one system.

Human responsibility and daily review

Each register has a responsible owner who verifies entries, weights, movements and dates before signing off the day. Accountability increases without increasing workload. Every department maintains a register with stock booked in and stock booked out. Production has multiple Batch Companions, which follow every production batch through all stages, along with detailed process descriptions and compliance validations.

AI pipeline and integration

Staff write in hardcover registers, the pages are scanned or photographed and AI extracts crate numbers, product descriptions, weights, dates and movements. Validation rules check the entries before they are added to the Master Excel Workbook. All stock and yield reports are then updated automatically.

Exception handling

Warnings highlight unclear writing, invalid codes, impossible weights or missing movements for human review. Management receives daily or minute-by-minute updates of all aspects of the business, including yields, stock on hand and daily output per department or machine.

The GENAU Master Workbook

The Master Workbook per department is an Excel whorkbook which contains the global crate register, room inventories, movement sheets, product master and the complete traceability and yield chain. It functions as the operational database of the factory.

ERP integration

GENAU aligns effortlessly with existing ERP systems by linking item codes, product names, batches, weights and crate mapping. No ERP modification is required.

Rollout roadmap

Implementation follows six practical steps: assessment, standardisation, pilot, expansion, full deployment and optional automation such as label printing, tablets or real-time dashboards.

Technical overview

The complete workflow moves from registers to scan, to OCR, to AI validation and then to the Master Workbook with optional ERP linkage. Reports include daily stock and FIFO checks, weekly yield and shrinkage trends and monthly audit and planning outputs. Requirements are limited to a PC, Excel, a smartphone or scanner and internet access.

In summary

GENAU converts a holistic system of manual records into a unified and continuously updated operational management system that provides complete stock visibility, reliable yields and strong traceability across the entire plant.