Rock Ledge Resources > Industries - Manufacturing > Representative Project - Improving Plant Performance – Packing Productivity

Improving Plant Performance – Packing Productivity

Business Challenge

The performance flour packing plant of a grain milling business was found to be less than expected when benchmarked against similar facilities. The business had the opportunity to capture significantly more packaged wheat flour business. The plant throughput was significantly lower that required to enable to business to take on the new trade. The options available to service this additional business were to increase running hours and take on additional resources or to improve the packing efficiency of the plant.

Solution

A Rock Ledge Resources Principal led the project to evaluate, develop and implement the actions required to improve the performance of the packing plant that would enable the output of the plant to support the additional sales captured by the business, without taking on additional resources. The performance of the plant was evaluated using Lean Six Sigma tools to identify which areas of the process were not under control, and to pin point where actions would deliver improved performance. An action plan was developed with supporting investment in physical resources, improving packing output and bringing down cost per unit.

Results

The packing rate was increased by greater than 30% across the board enabling the business to take on the new trade, without increasing resources or operating hours of the plant, reducing the cost per unit for the new business.

Relationships: John Hunter | Operational Excellence | Manufacturing