Case Studies 

Feldhues www.feldhues.de 

Feldhues is the inventors of the character meats concept for kids. Developing children's cooked meat products with design for over 30 years. Based in Clones Co Monahan. 

Overall Savings - in excess of €250k 

Situation 
The Feldhues site based in Clones, Co Monaghan mainly serves the English and Irish markets and now also produces, besides kids’ novelty sausage, classic sausage specialities. 
It also runs state-of-the-art slicing and packaging lines for pre-pack in diverse formats. 
Competing in the Global Market is bringing about ever-growing challenges such as increased raw materials costs, expanding international competition and exposure to the impacts of exchange-rate fluctuation and Brexit. By implementing Lean Manufacturing and Lean Tools, Management were confident that this would develop cost-competitive processes and provide a platform to better compete in a wider market. 
Pembroke Alliance was commissioned to facilitate the Lean Plus Programme on behalf of Enterprise Ireland. 
 
Objectives 
The main objectives of the programme would be to concentrate on; 
Reducing the level of rework on product, 
Increasing Productivity levels, and 
Embedding a culture of Lean 
Key Challanges 
Culture – managing change, removing the doubt & fear concerning the programme 
External Factors - Increase in Raw Material Prices, Brexit 
Availability of Production Staff 
Getting staff used to the accountability that comes with having production metrics in place. 
Key Changes 
Staff highly engaged, more forthcoming with ideas and suggestions 
Ideas being welcomed and assessed using the principles of Lean / Six Sigma 
Staff Trained to Green & Yellow Belt levels 
Targets agreed and set and performance measured 
Increased awareness through improvement communication. 
Accurate system for measuring the output of each machine and operator- Lean Transform funding 64% of € 416,000 cost 
Key Results 
Identified and eliminated a series of Wastes in the production process 
Designed a template that will gather daily Production Volumes that can be used to drive Business Improvements. 
Developed a Dashboard displaying productivity performance, with implementation of Visual Platforms to Share Daily Performance against standard 
Installed a new lean purchasing system that will analyse Suppliers by Product and allow the business to tender more effectively in the future. 
Productivity on the Main Packaging line increased by c.21%, Improving Capacity and Lead Times, while reducing Waste and Rework levels in the process 
Overall Savings generated in this program were in excess of €250k 
All of this was achieved in a team effort without any capital investment. 
The Business have continued their lean journey, they are now in their 2nd Lean Plus project. 

Feldhues www.feldhues.de 

Feldhues is the inventors of the character meats concept for kids. Developing children's cooked meat products with design for over 30 years. Based in Clones Co Monahan. 
Situation 
The Feldhues site based in Clones, Co Monaghan mainly serves the English and Irish markets and now also produces, besides kids’ novelty sausage, classic sausage specialities. 
It also runs state-of-the-art slicing and packaging lines for pre-pack in diverse formats. 
 
With increased competition and global markets become increasingly challenging, with high labour costs, FX exposure and BREXIT, Management decided that by implementing Lean Manufacturing and Lean Tools to the business would improve operational processes and allow the business to compete better in the open market. 
 
Pembroke Alliance was commissioned to facilitate the Lean Plus Programme on behalf of Enterprise Ireland. 
Objectives 
The main objectives of the programme would be to concentrate on; 
Reducing the level of rework on product, 
Increasing Productivity levels, and 
Embedding a culture of Lean 
Key Challanges 
Culture – managing change, removing the doubt & fear concerning the programme 
External Factors - Increase in Raw Material Prices, Brexit 
Availability of Production Staff 
Getting staff used to the accountability that comes with having production metrics in place. 
Key Changes 
Staff highly engaged, more forthcoming with ideas and suggestions 
Ideas being welcomed and assessed using the principles of Lean / Six Sigma 
Staff Trained to Green & Yellow Belt levels 
Targets agreed and set and performance measured 
Increased awareness through improvement communication. 
Accurate system for measuring the output of each machine and operator- Lean Transform funding 64% of € 416,000 cost 
Key Results 
Identified and eliminated a series of Wastes in the production process 
Designed a template that will gather daily Production Volumes that can be used to drive Business Improvements. 
Developed a Dashboard displaying productivity performance, with implementation of Visual Platforms to Share Daily Performance against standard 
Installed a new lean purchasing system that will analyse Suppliers by Product and allow the business to tender more effectively in the future. 
Productivity on the Main Packaging line increased by c.21%, Improving Capacity and Lead Times, while reducing Waste and Rework levels in the process 
Overall Savings generated in this program were in excess of €250k 
All of this was achieved in a team effort without any capital investment. 
The Business have continued their lean journey, they are now in their 2nd Lean Plus project. 
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