FMCG Processed Foods
Lean Transformation Case Study
Mexican Company in the market for processed food (>15 production factories in Mexico and the US)
PROBLEM
– No significant achievements through various previous CI projects/initiatives
– Improvement required in production lines efficiency and defects
– Increase improvement in filling lines, mainly due to Break Downs and Short Stops
SOLUTION
- Introduction of Total Productive maintenance (Governance, Pillars, methodologies)
- Launching Shop Floor Management system (Daily Management Systems – TPM/DMS)
- Focused Improvement tools implementation
- Autonomous Maintenance
- Planned Maintenance
- Quality Maintenance
RESULTS
- OEE increased from 43% to 64%
- Line Mechanical Efficiency increased from 86% to 95%
- Production time utilization increased from 85% to 91%
- Material waste reduced from 2.17% to 1.10% in total for 50%