FMCG Food & Beverage

Green-field Case Study

One of the leaders in food and beverage production world-wide.​

PROBLEM

– The client builds a green-field factory for production of spices and easy meal solutions with over 600 production employees. The challenge is to run production with implementation of Lean and TPM practices from the start, to help solve the occurring issues in a standard manner and make sure ramp up and launch of new products is smooth.​

– The equipment used is not new but delivered from other factories, and not always manufactured for the exact types of packaging for client’s SKUs.​

– Green-field factory is located in a rural area with tremendous shortage of qualified specialists, engineers and managers. ​

SOLUTION

  • Supervisor development 
  • Introduction of Total Productive maintenance (Governance, Pillars, methodologies) 
  • Focused Improvement tools: DMAIC, SMED, A3, PDCA
  • Suggestion scheme revision, establishment of communication platform 
  • Expert training and best practices exchange  

RESULTS

  • 20% Improvement in reliability of equipment via TBM and CBM calendars, autonomous maintenance, capability development of technicians ​
  • Asset intensity increase by 8%
  • Short stop reduction by 40%
  • Engagement of employees over 75% (by the culture and engagement survey results) 
  • 70% of new product introduction are at vertical start up