Published in: Case Studies

Optimized processes, efficient work-order systems for a FMCG Confectionary producer

Author Team Allied Biztech

Published on: August 20, 2020

Background:

Our client, a growing confectionery producer with over 2,00+ employees and a pan Asia presence across 3 countries, holds a significant position in the FMCG market. With a substantial turnover and rapidly growing market share, the company sought to enhance productivity and efficiency to maintain its competitive edge.

Challenges:

The client faced several challenges that hindered their operational efficiency:

1. Lack of Standard Maintenance Procedures: The absence of standardized maintenance processes led to inconsistencies and inefficiencies in their production systems.
2. Implementation of an Efficient Work-Order System: The client recognized the need for a unique work-order system to streamline operations, reduce unnecessary workload, and ensure better resource allocation.
3. Infusing Continuous Improvement Mindset: The company aimed to foster a culture of continuous improvement within its workforce, driving innovation and problem-solving at every level.
4. Root Cause Analysis Methodology: Identifying and addressing the root causes of operational issues was essential for sustained growth and optimized performance.

Solution:

Allied Biztech stepped in as a strategic partner to address these challenges comprehensively. Through a meticulously planned approach, the following solutions were implemented:

1. Process Optimization: Allied Biztech conducted a thorough analysis of the client’s existing processes and identified bottlenecks. With a high-level process redesign, we streamlined operations, eliminating redundancies and optimizing workflow.
2. Work-Order System Implementation: Our team developed and integrated a customized work-order system that automated various tasks, enabling efficient resource allocation and reducing downtime.
3. Cultivating Continuous Improvement: We introduced training and workshops to instill a culture of continuous improvement among the employees. This approach encouraged the workforce to proactively identify areas for enhancement and take necessary actions.
4. Root Cause Analysis: Allied Biztech guided the client’s team on implementing a robust root cause analysis methodology. This approach helped identify the underlying reasons behind operational issues, enabling data-driven decision-making and targeted improvements.

Key Performance Indicators (KPIs) Improved:

The collaborative efforts between the client and Allied Biztech resulted in significant improvements across various KPIs:

1. Workload Reduction: By optimizing processes and implementing the work-order system, the client witnessed a substantial reduction in planned and unplanned workload, leading to increased overall efficiency.
2. Enhanced Planning and Critical Activity Management: The project enabled the client to improve their job planning processes significantly. They could now better manage critical activities, ensuring timely project completion.
3. Productivity and Synergies: The combined efforts of the client’s workforce and our strategic interventions resulted in enhanced productivity levels and the realization of synergies in their operations.

Conclusion:

Through a meticulous and client-focused approach, Allied Biztech successfully helped the confectionery producer optimize its operations, enhance productivity, and foster a culture of continuous improvement. The implementation of standardized maintenance procedures and a unique work-order system enabled the client to streamline processes, resulting in increased planning efficiency and reduced workload.