Manufacturing Case Study
Client Profile
A retail spice manufacturer aims to improve efficiency and reduce conversion costs.
Solutions
- Management Operating System (MOS)
- Training & Development
- Centerlining
- Root Cause Analysis
- Leader Standard Work
- Visual Management
- Material Yield Optimization
- Changeover Cycle Compression
Challenge
- High levels of unplanned equipment downtime
- Supervisors and managers spending extensive days “firefighting”
- Unclear equipment run-standards, reducing output
- Poor decision-making due to inadequate metrics and system structure
- Ineffective problem solving leading to recurrent failures
- Yield losses due to spillage and overfills
Approach
- Identified meaningful KPIs to prioritize efforts in improving plant profitability.
- Installed shop floor visual management to promptly address variances at the source of loss.
- Coached meeting behaviors to drive actions to address poor line performance.
- Implemented Leader Standard Work for line leads, supervisors, and managers to aid prioritization and establish a consistent cadence.
- Performed deep cleaning and repairs on problematic line equipment.
- Established clearly visible “run-right” settings on equipment to optimize product throughput.
- Created a changeover matrix with significantly reduced target times, applying SMED principles.
- Developed a process to escalate and resolve the root causes of systemic issues.
- Installed sustainability audits to maintain progress and foster continuous improvement.
Results
- Achieved effective and accelerated start-ups and recoveries from downtime events.
- Reduced plant-wide unplanned downtime, driven by enhanced problem-solving capabilities.
- 19% reduction in labor cost per case in just four months.
- 23% improvement in yield loss and ingredient spend.
- Increased Preventative Maintenance compliance from 40% to 89% through improved working disciplines.
- Increased line uptime across all production lines.
- Line 1: ~50% raised to 65%
- Line 2: ~60% raised to 80%
- Line 3: ~65% raised to 85%
