A Large German based FMCG company were struggling with operating performance at one of their flagship sites in Munich. The company were experiencing poor operational efficiencies and reliability impacting cost and service delivery. They needed someone with experience in the implementation of lean continuous improvement methodologies to assist them to turn the performance of the production environment around.

In order to address the production performance fo the manufacturing site Brett was requested to create a site strategy that would use a “Lean” approach to unlock opportunities to improve performance.

In collaboration with the site management team and Director, mapped the site losses identifying problems affecting performance and translating these into a prioritised set of opportunities for improvement.

1. Identify the key issues affecting site performance
2. Provide strategy following a prioritised approach to address these issues
3. Develop the site management team and key resources skills required
4. Deploy strategy for Autonomous Maintenance, Preventative Maintenance and Focussed Improvement
5. Guide teams through implementation of projects addressing root causes and maintenance strategies
6. Provide guidance on global best practices in continuous improvement

The site director and management team now had a clear strategy, methodology and approach to drive a culture of continuous improvement on site.

Projects closed in 3 months yielded a 4% increase in opperational efficiency with a further 20% identified for further improvements by following the same methodology.

Root Cause project closure time reduced from 6 months to 1.5months, increasing project closure rate by 4 times and unlocking an opportunity for the company to go after 4 x as many projects each year.

A clear strategy to address breakdowns and factory reliability based off of proven success.

• lean
• Digital Manufacturing
• Remanufacturing
• Manufacturing Execution System (MES)

• Manufacturing