Sun-Rype Products Ltd. – Increased capacity, profit
“The consultants from Grant Thornton Productivity Improvement worked closely with our managers and staff using a professional and participatory approach to implement sustainable improvements. They delivered on their commitment. I would recommend their services and would use them again should a similar need arise.”
Project cash flow
Objectives
- Redesign and implement enhanced management systems
- Improve management capability
- Increase capacity
- Increase profit
Enhanced management systems
- Installed new planning and scheduling tools for maintenance functions
- Consolidated and developed reporting tools for food, beverage, and maintenance operations
- Developed planning and performance evaluation tools to ensure effective deployment of resources
Improved management capability
- Delivered applied management training program to management
- Provided coaching for supervisors towards effective management of shop floor execution
- Drove analysis of employee skill gaps and execution of training plans to support reduction of operational variances
- Increased accountability of supervisors based on achieving clearly defined targets
Increased capacity
- Improved production scheduling system using measured standards
- Defined individual and collective production targets and expectations
- Reduced maintenance backlog through improved work segregation
- Increased machine availability and performance by shifting maintenance focus from primarily reactive to proactive
Increased profit
February 18, 2008
-
- PRINT SIZE:
-
-
Client
Sun-Rype is a leading Canadian consumer-packaged goods company producing juice and fruit snack products.
- Mid-sized public company with unionized work force
- Single site production facility with sophisticated packaging technology
- Expanding product lines and growing revenues
Competitive environment
- Market dominated by large global players with deep pockets and strong brands
- Few large customers holding significant negotiating power
- Levers - quality, flexibility, price, inventory management
Situation
- Highly variable demand over a growing number of products
- Customer expectation of responsiveness requires increased production flexibility
- Capacity constraints in current facility limit strategic opportunities for growth
- Limited labour supply and inefficient resource allocation
- Opportunity to reduce labour and material waste in production chain
Results
- Project return on investment of 3.5:1
- Improved productivity by 25%
- Reduction in line downtime of 15%
- A 50% reduction in volume of rush orders for parts
- Reduction in packaging and material waste