Following a major capital investment at this blue-chip food manufacturer in the UK, the management team was fighting the process and delivering very low productivity and high unit costs.
I was brought in to reverse the trend and over an 18 month period identified structural weakness in the operational structure that lead to several key changes.
- Shift patterns harmonised from 8 to 1.
- We implemented a “lite” Total Performance Management methodology to bring ownership of the line and its performance back to the people running it.
A further capital investment plan was then agreed to improve the previous installations and to add improved utilities resilience, vehicle flows around the site, staff facilities, improved air flows to reduce mould risk and improve working conditions on the shop floor and a more flexible packing department to meet the needs of the market.
This project yielded fantastic results including:
- A reinvigorated the Hearts and Minds programme delivering over 650 days without a RI.
- Stabilised BIC customer delivery rate leading to lowest ever stock days in UK dry pet foods.
- Achieved ISO 22000, 14001 & OHSAS 18001 & First UK factory to achieve the advanced Quality Management system & rated “Good” in Group Audit.
- Re-organised the technical and operations functions to focus on delivery using NCE / TPM principles bringing a 30% improvement in operational efficiency.
We contributed to the year on year reduction in cost of goods sold from site, helping to improve UK profitability whilst also raising engagement of the teams through goal alignment of the daily operational review structure (in line with TPM best practice).
4pManagement Ltd 
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