CASE
STUDIES

Enterprise

Initial Situation:

At the beginning of this 12 month period the plant was running with 2 production lines with a capacity of 16,000 loaves of bread per hour. DIFOT was being maintained at a high level but only through significant overtime. Plant KPI’s were in place and were running at an overage of:

Improvement Approach:

The approach taken to make improvements was based around rigorous analysis of production and engineering data combined with rapid implementation of corrective actions.
Twice daily the improvement team would collect production data including detailed descriptions of all downtime and causes of waste. Through the analysis of a standard Pareto chart each day the top 2 reasons were fully investigated and corrective actions put in place to ensure there was no recurrence.

The Results:

Improvements in machine reliability in an industrial bakery environment quickly flow through the business.
Less breakdowns mean less waste and more consistent production. This in turn led to more consistent quality, more reliable deliveries and an overall improvement in the consistency of business operations.

Business

At the beginning of this 12 month period the plant was running with 2 production lines with a capacity of 16,000 loaves of bread per hour. DIFOT was being maintained at a high level but only through significant overtime. Plant KPI’s were in place and were running at an overage of:

Initial Situation:

Running 16 hour production shifts each day and with a new contract about to come on line this bakery had an urgent need to increase line output to enable additional volume to be made on the existing line.

On the line downtime, waste and giveaway were recorded manually with pen and paper and these figures were presented to the management team on a weekly basis. It was not the norm for this critical production information to be filtered down to the front line staff and there was not usually any pro-active follow up on the issues that were recorded.

Improvement Approach:

After spending time observing the line in operation it was evident that there was excessive downtime and giveaway that was not being recorded or acted upon. LiveBake initially undertook a staged approach to data collection:

  • Establish an Excel spreadsheet to collate and communicate the recorded line measures, at this point it was found that 20 minutes downtime and 4% giveaway a day was being recorded
  • Introduce LiveBake computer data entry point to replace the traditional pen and paper, this gamification increased the recorded downtime from 20 minutes to 60 minutes and the recorded giveaway from 4% to 5%.
  • Connecting LiveBake directly to the line equipment to gain exact downtime measurements led to the recording of over 150 minutes of downtime per shift and an increase in giveaway recording to 7%

Baseline:

This process completed over the period of 4 weeks allowed the establishment of the project baselines:

Factory In Your Pocket - Improvement Approach:

The creation of the base line or ‘current state’ enabled both the bakery and LiveBake to agree on the next course of action; reduction in downtime and giveaway.

A project team was established to drive these improvements using both LiveBake standard reports and detailed Factory in Your Pocket analytics provided through Yellowfin software. Using standard improvement techniques combined with formal Root Cause Analysis and 5-Why investigations the team was able to identify and reduce the causes behind significant downtime and excessive giveaway. information to be filtered down to the front line staff and there was not usually any proactive follow up on the issues that were recorded.

Results:

In this project the Giveaway savings were a direct impact to the bottom line profit of the business. The total cost benefit to the business was $375,000 per year.

Factory in Your Pocket worked with and supported the site team over a period of 4 months, since the completion of this project the team have been able to undertake similar analysis and improvement without external support.

logo
MELBOURNE   |   JAKARTA   |   KUALA LUMPUR

Log in with your credentials

Forgot your details?