Operational Excellence
European beverage manufacturer with annual revenues >€1 billion across 9 markets; Brewing capacity of 20 million hectolitres from 14 breweries; Coca Cola’s 5th largest bottler world-wide with 420 m unit cases per annum.
Key Deliverable: Operational excellence programme increasing OEE by an absolute 22% and labour productivity by 30%.
Approach:
- Joint approach to ensure ownership and transfer of learning
- Resource requirements planning included changing shift patterns and introducing flexible working to accommodate seasonality without overtime or shift premium costs
- Zero-basing of directs, indirects and administrative staff
- Working methods changes, reduction in set-up times and increased machine speeds
- Reduced materials wastage and losses
- Improvement in employee engagement, morale and attitude
- Implementation of scorecard and PDCA management cycle at all levels
