Case studies

Relevant service: Business Transformation, Operational Excellence, Total Productive Manufacturing

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Improving Asset Reliability in a Bottling Plant

About the Company

A major international food & drink manufacturer.

The Challenge

Our customer recognised that in order to fulfill an increase in sales of one of their main product lines to retail customers they needed to improve productivity. They had achieved some significant improvements already through line optimisation. This has been carried out to reduce product waste, reduce product giveaways, and reduce manufacturing cost per kilo. Whilst this had improved and stabilised performance the rate of further improvement was proving to be a challenge.

What We Did

We developed a bespoke, practical training intervention package using the 10/20/70 philosophy, tailored to address the needs identified during the scoping study and designed for all levels, from operatives to senior management. A desired future state was established, with the site aiming to increase production capacity from 7,000 tonnes to 9,000 tonnes per day. We optimized the changeover process to reduce time, minimize waste, and eliminate variability. A pilot program was deployed on key production line assets, which is now being rolled out across the site. Additionally, we developed and aligned standards, ensuring skills and knowledge were shared consistently across the organization.

Results

The program delivered significant improvements, with Overall Equipment Effectiveness (OEE) increasing from 42% to 57%, a level sustained by the site team. Teams became highly engaged, and their skills improved throughout the process. The pilot program was a success, building capability for a site-wide rollout. Champions were identified and upskilled to govern the program effectively, ensuring its long-term sustainability. Additionally, the site achieved milestone one on its journey toward the ultimate goal of zero accidents, defects, breakdowns, and minor stops.

Framework

Total Productive Manufacturing

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