Key Business Challenges and Project Objectives:

In April 2015, the milk quota in Ireland was removed, which resulted in Food Processing facilitates planning to increase capacity to match supply from Farmers. Our client, a leading provider of dairy produce to the Kerrygold brand decided in 2013 to deploy Lean into their organisation to prepare for this significant growth. They invited Crystal Lean Solutions to support this Lean Transformation.

CLS Approach and Changes Implemented:

Using the Hoshin Planning approach, CLS first worked with the Leadership team to determine and communicate the strategic goals of the business. Working across all aspects of the business, twelve Lean Six Sigma Green Belt projects were identified, training was completed and projects mentored and managed through a new Project Management Process. Project leaders included Production Operators, Laboratory technicians, Supply Chain and Managers. Other Lean elements implemented included:

  • 5s (A place for everything, communication boards, information boards, signage) in production
  • Balanced Scorecards to manage Operations and Health and Safety performance
  • OEE program to understand and reduce the main contributors limiting production performance
  • A cross functional communication process to manage daily production

Results / Outcomes:

  • Achieved €300k cost savings (annual)
  • Introduced a process based approach to systematically manage the business
  • Introduced a culture of data based decision making
  • 5s provided a foundation to compliance to Food Quality standard

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