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BOOST Throughput and BUILD Capabilities for a Leading Producer of a Private Label Packaged Foods and Beverages

Client Context

  • US based producers of private label snacks, beverages, & meal preparation with 40 sites generating over $4B of annual revenue

Key Challenges

  • Desperate need for capacity release to fulfill demand for certain product lines
  • Low Overall Equipment Efficiency (OEE)
  • Deterioration of existing equipment
  • New equipment was not performing at desired level
  • Turnover causing management and labor shortages
  • Lack of leadership, as well as operational and problem solving skills

Approach & Key Success Factors

  • A detailed site assessment that included
    • Loss analysis on OEE, material, and supply chain
    • Maturity assessment on OpEx systems, organization & behavior
    • Co-creation of the implementation plan
  • A BOOST Phase to make quick performance improvements and install controls on critical production lines
  • A BUILD Phase to develop capabilities to expand and sustain performance

Results

BOOST performance and BUILD capabilities for 7 priority manufacturing sites in 2 years

4-9%

Points increase in OEE

12-17% 

Increase in throughput

 

Food & Beverage Case Studies
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