Manufacturing Case Study
Client Profile
Retail Spice Manufacturer.
Solutions
- Management Operating System
- Training & Development
- Centerlining
- Root Cause Analysis
- Shop Floor Situational Coaching
- Visual Management
- Material Yield Optimization
- Changeover Optimization
Challenge
- Low productivity resulting in $3M in lost sales monthly.
- High levels of unplanned equipment downtime.
- Insufficient supervisor and manager presence on the floor.
- Unclear equipment run-standards, leading to reduced output.
- Poor decision-making due to inadequate metrics and flawed system structure.
- Ineffective problem-solving leading to recurrent failures.
Approach
- Developed “Metrics that Matter” to focus efforts on improving plant profitability.
- Installed shop floor visual management to promptly address variances at the source of loss.
- Coached meeting behaviors to prompt actions addressing poor line performance.
- Eliminated factory silos and aligned management with site imperatives towards common goals.
- Conducted a deep clean and repaired “bad actors.”
- Established clearly visible “run-right” settings on equipment to optimize product throughput.
- Initiated Statistical Process Control and weight management on bottle fillers to minimize yield loss from overfill.
- Created a process to escalate and resolve the root causes of systemic issues.
- Implemented sustainability audits to maintain progress and facilitate continuous improvement.
Results
- Delivery targets are now consistently met, with zero lost sales opportunities.
- Achieved a 20-point/43% improvement in line availability/uptime.
- Yield savings are equivalent to 38,000 cases annually.
- Improved changeover performance and efficiency.
- Quicker start-ups and recoveries from downtime.
- Overall enhanced focus and a performance-driven mindset among leadership.
