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

Client Context

• U.S. based producers of private label snacks, beverages, & meal kits with multiple sites generating multi billion dollars 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 several priority manufacturing sites in 2 years

4-9%

Points increase in OEE

12-17% 

Increase in throughput