Food Industry LEAN Process Improvement Example

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CASE STUDY

CASE STUDY – Fresh Cream Cake Manufacture

Many companies, in order to improve production will put more people on a line, however if a “Time and Motion Study” was applied then higher production and productivity could be achieved – without increasing manning costs…

This Case Study highlighted where production could be improved at NO COST ( extra sales value circa £2.0M )

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Waste In Food Manufacturing

FRESH CREAM CAKE MANUFACTURE – PACKING:

  • Production lines are running 40hrs/wk – 52 wks/yr… 
  • The company running 3 production lines
  • People per line = 12. ( total 36 people )
  • Operators are working around 70% efficiency
  • Lines producing around 1260 per hour ( total 3780 

Also with the way the line is run much of the product ends up on the floor.

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Food Manufacturing Improvement

FRESH CREAM CAKE PACKING – Future State:

  • Apply a Time and Motion Study
  • Apply Flow-Line-Balancing Takt Times
  • Lets now operate and run 4 production lines
  • People per line = 8 + runner = 9 ( total 36 )
  • Operators now working at around 90%
  • Lines now producing 1800 per hour ( total 7200 )

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THE CHANGE PROCESS:

  • Time and Motion Study and LEAN Line Balancing
  • Takt Time / Cycle Time cementing the new improvements
  • Standard Work Procedures cementing “Best Practice Methods”

Experience doesn’t just come from working in the food industry but from working in many different sectors…

This Project Could Realise An Extra Sales Value circa £2.0M

Opportunity and a fresh pair of eyes is all that is needed…

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If You Have Any Questions, We Are Happy To Help:

For over 30 years we’ve designed and implemented “Business Initiative Improvement” Projects.

Atherton Management Services Ltd:  We help people in business improve their business.

Please Contact Us, tell us your issues – tell us how you would like to improve your business. 

For More Information – Please call us…  UK – 07300 788 486 or Contact Us By E-Mail