Implementing an Operational Excellence Program in the Beer Sector
Client Context
- An international leader in the beer sector with activities in over 70 countries and more than 150 breweries spread across the globe
Key Challenges
- The company decided to launch a global Continuous Improvement initiative to generate cost efficiency improvements to support new acquisitions while at the same time creating a common ‘way of working’ throughout its Supply Chain Operations
Approach & Key Success Factors
EFESO supported the client in:
- Co-designing its customized Operational Excellence Program framework
- Deploying it progressively in the operating units
- Designing and delivering on-the-job training to thousands of employees on OpEx methodologies to build internal capabilities for an autonomous roll-out
- Co-creating the client’s methodological ‘OpEx Toolbox’ with all main pillars in manufacturing and logistics
- Providing plant leadership teams with a step change in their change management skills through training programs
- Facilitating the process for High Performance Organizational design of their future operating units
Results
20%+
OEE improvement
22%
Material waste reduction
12%
Transportation cost reduction
35%
Reduction in fixed & variable costs
700
Certified PKE™ employees able to successfully drive Continuous Improvement both in manufacturing and logistics
An extended Continuous Improvement culture throughout the entire organization with all 150 breweries consistently running the OpEx Program
In the first 8 years of the OpEx Program implementation, productivity doubled
A fully embedded change management capability in most operating units