FOOD · SANITATIONROI 2 Months
35% Reduction in Sanitation Time
End-of-shift sanitation time was reduced from 4 hours to 2.5 hours.
Unplanned Downtime−35%
Setup Average−30%
OUR SECTOR-SPECIFIC REFERENCES
Companies We Are a Solution Partner To
We work side by side on the shop floor with food, beverage and agricultural product manufacturers.
Rising raw material costs, cost pressure that cannot be passed on to prices at the same speed, supply chain disruptions and tightening food safety requirements expect food manufacturers to work fast, error-free and at lower cost, all at once.
OUR VIEW OF THE SECTOR
Flexibility and Efficiency Matter in the Food Sector
As Gemba Partner, we address the production system end to end, from line efficiency to product changeovers, from cleaning and hygiene processes to warehouse and shipment flow and daily shop floor management.
We make breakdown and stoppage losses visible on filling and packaging lines, shorten product and format changeover times, and reduce scrap and waste. We enable fast launch of new products on the line, and secure quality and food safety on the shop floor with standard work and visual management systems.
The goal is to build an operation that meets demand on time, without loss and safely, whatever the season brings.
GET EXPERT ADVICE ON THIS TOPIC
Schedule a free assessment call tailored to your shop floor.
90 daysMeasurable result
6–9 monthsTotal project duration
2 monthsAverage ROI
PROVEN SUCCESS STORIES
Real Results from Shop-Floor Experience
Explore the related service →
FOOD PRODUCTION · HIGH-SPEED FILLINGROI 2 Months
OEE from 62% to 80% on a High-Speed Filling Line
Micro-stops, speed losses and setup problems were analyzed on the shop floor. By improving equipment parameters and work standards, additional capacity was created on the existing line.
OEE62% → 80%
Additional Capacity+7 Days/Month
PACKAGING · PRODUCTION LINEROI 2 Months
35% Increase in Line Speed
Bottlenecks, micro-stops and speed losses on the production line were analyzed. By improving process parameters and working standards, the capacity of the existing line was increased without investing in new equipment.
Line Speed+35%
Production Capacity+30%
PACKAGING · PRINTING PROCESSESROI 1 Month
80% Improvement in Printing Setup Times
The product changeover process was analyzed step by step with the SMED approach. Internal and external setup activities were separated, and preparation, adjustment and commissioning operations were standardized.
Setup Time−80%
Usable Capacity+25%
CHEMICALS · EQUIPMENT RELIABILITYROI 2 Months
40% Reduction in Critical Machine Downtime
Root causes of unplanned stops were analyzed; preventive maintenance, operator checks and critical equipment standards were restructured. Production continuity and equipment reliability were increased.
Unplanned Downtime−40%
MTBF+35%
DURABLE CONSUMER GOODS · PAINT SHOPROI 1 Month
100% Increase in Paint Shop Efficiency
Downtime, speed and capacity losses in the paint shop process were analyzed. By eliminating bottlenecks and improving working standards, output from existing equipment was doubled.
Production Efficiency+100%
OEE+40%
OUR SERVICES
Our Services That Drive the Transformation
From Operational Excellence and Lean Transformation to digital shop floor management, from factory layout to capacity development, we address your production system end to end.
OUR SECTOR-SPECIFIC REFERENCES
Companies We Are a Solution Partner To
We work side by side on the shop floor with food, beverage and agricultural product manufacturers.
Rising raw material costs, cost pressure that cannot be passed on to prices at the same speed, supply chain disruptions and tightening food safety requirements expect food manufacturers to work fast, error-free and at lower cost, all at once.
Flexibility and Efficiency Matter in the Food Sector
As Gemba Partner, we address the production system end to end, from line efficiency to product changeovers, from cleaning and hygiene processes to warehouse and shipment flow and daily shop floor management.
We make breakdown and stoppage losses visible on filling and packaging lines, shorten product and format changeover times, and reduce scrap and waste. We enable fast launch of new products on the line, and secure quality and food safety on the shop floor with standard work and visual management systems.
The goal is to build an operation that meets demand on time, without loss and safely, whatever the season brings.
GET EXPERT ADVICE ON THIS TOPIC
Schedule a free assessment call tailored to your shop floor.
90 daysMeasurable result
6–9 monthsTotal project duration
2 monthsAverage ROI
PROVEN SUCCESS STORIES
Real Results from Shop-Floor Experience
FOOD · SANITATIONROI 2 Months
35% Reduction in Sanitation Time
End-of-shift sanitation time was reduced from 4 hours to 2.5 hours.
Unplanned Downtime−35%
Setup Average−30%
FOOD PRODUCTION · HIGH-SPEED FILLINGROI 2 Months
OEE from 62% to 80% on a High-Speed Filling Line
Micro-stops, speed losses and setup problems were analyzed on the shop floor. By improving equipment parameters and work standards, additional capacity was created on the existing line.
OEE62% → 80%
Additional Capacity+7 Days/Month
PACKAGING · PRODUCTION LINEROI 2 Months
35% Increase in Line Speed
Bottlenecks, micro-stops and speed losses on the production line were analyzed. By improving process parameters and working standards, the capacity of the existing line was increased without investing in new equipment.
Line Speed+35%
Production Capacity+30%
PACKAGING · PRINTING PROCESSESROI 1 Month
80% Improvement in Printing Setup Times
The product changeover process was analyzed step by step with the SMED approach. Internal and external setup activities were separated, and preparation, adjustment and commissioning operations were standardized.
Setup Time−80%
Usable Capacity+25%
CHEMICALS · EQUIPMENT RELIABILITYROI 2 Months
40% Reduction in Critical Machine Downtime
Root causes of unplanned stops were analyzed; preventive maintenance, operator checks and critical equipment standards were restructured. Production continuity and equipment reliability were increased.
Unplanned Downtime−40%
MTBF+35%
DURABLE CONSUMER GOODS · PAINT SHOPROI 1 Month
100% Increase in Paint Shop Efficiency
Downtime, speed and capacity losses in the paint shop process were analyzed. By eliminating bottlenecks and improving working standards, output from existing equipment was doubled.
Production Efficiency+100%
OEE+40%
OUR SERVICES
Our Services That Drive the Transformation
From Operational Excellence and Lean Transformation to digital shop floor management, from factory layout to capacity development, we address your production system end to end.