Using Lean to Improve Operational Processes & Compete Better in the Open Market

The Situation

Food production facility with increased competition and increasingly challenging markets, high labour costs, FX exposure and BREXIT.

Management decided that by implementing Lean to the business would improve operational processes and allow the business to compete better in the open market.

A Quote from the Client

MANAGING DIRECTOR:  “….We have had a very good trading year and Pembroke have been a real help in this. Getting Lean going has been one of my best and most successful decisions as a Managing Director...”

The Objectives & Challenges

The main objectives of the programme would be to concentrate on;

•       Reducing the level of rework on product

•       Increasing productivity levels

•       Embedding a culture of Lean

The Actions

•       Identified and eliminated a series of Wastes in the production process

•       Staff highly engaged, with ideas and suggestions

•       Staff Trained to Green & Yellow Belt levels

•       Targets agreed & set with performance measured

•       Increased awareness through better communication.

•       Accurate system for measuring the productivity

The Outcomes

Introduced Lean Tools to eliminate Wastes and build Capacity

Implemented and embedded a Culture of Lean to develop capacity to allow the company to Grow.

·      Turnover up from €5m to €13m

·      EBITDA Margin up from 5% to 11%