Waste reduction and process re-engineering results in over €1M savings
CASE STUDY - FOOD PRODUCTION
The Situation
Our customer had state-of-the-art slicing and packaging lines for pre-pack in diverse formats.
With increasing competition and global markets becoming increasingly challenging, the management team decided to look at lean manufacturing and lean tools to improve operational processes.
Pembroke Alliance was commissioned to facilitate the lean plus engagement on behalf of Enterprise Ireland.
The Objectives & Challenges
The main objectives of the programme were to concentrate on:-
Reducing the level of rework on product
Increasing overall productivity levels
Embedding a culture of lean
In order to achieve these objectives a number of challenges had to be overcome:
Culture - managing change, removing doubt and fear concerning the programme
External Factors - raw material prices & Brexit
Availability and accountability of production staff
COVID-19 - Restricted face-to-face enagement
“Pembroke Alliance helped us to think about our business differently - to identify non-value add activities as waste and to create a culture of continous improvement”
A quote from the owners
The Outcomes
The following outcomes were achieved:-
Identified & eliminated a series of wastes in the production process
Developed a dashboard system displaying productivity performance across a number of visual platforms
Productivity on the main packaging line increased by 21% improving capacity and lead times
The business has established an internal lean team that independently continues to drive improvements
Overall savings generated so far have surpassed €1M
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