Mass Balance Audits

Mass Balance Audits

Mass Balance Audits that identify yield, report shrink, show how to improve plant floor efficiencies.

DSI's Mass Balance Plant Audits assist dairy and food product manufacturers identify and report shrink, yield and quality improvement opportunities directly from their plant floor systems to their financial system for accurate and timely cost analysis.


  • Current solution and constraints analysis
  • Process variance analysis:
  • By process zone
  • Cause & effect correlation
  • Probability analysis
  • Range versus impact analysis
  • Measurement system
  • Baseline & goal determination
  • Process capacity/utilization analysis
  • Current/future state data flow analysis

Customer Benefits Include:

  • Greater yields (0.1% - 2.0%)
  • Increased quality via reduced variations
  • Reduced shrink (o.1% - 5%)
  • Accurate inventory management
  • Accurate and timely manufacturing costs analysis
  • Greater component level tracking (Protein, Fat, etc.)
  • Greater customer satisfaction

Solutions recommendations:

  • Rough cost and time estimates
  • Prioritized by ROI payback model
  • Standard operating procedures
  • Data/information plan - ERP
  • Technologies Utilized & Evaluated:
  • Plant floor automation systems
  • Plant floor and Laboratory instrumentation
  • Six Sigma quality systems RDMAIC
  • Project Management Institute standards
  • Linear correlation analysis
  • Predictive model control systems
  • Lean Manufacturing methods