This client operates a multi-line processing plant, producing 200+ ready to eat poultry products. Operating challenges included minimal stocks due to short shelf life, max 24 hour order lead times and stringent service level targets.
Due to ongoing volume growth and increased product mix complexity, we were requested to complete an objective modelling of the site’s throughput capability. This included intake, preparation, cooking, packing, final product storage and movement offsite. We also reviewed raw material supply, production planning and line scheduling processes.
The exercise identified a number of process improvement opportunities to minimise identified bottleneck elements across the site.
NI Dairy Group
Our client has a number of manufacturing facilities in NI and GB, producing a broad range of bulk commodity and chilled consumer products.
MDR were requested to evaluate each site’s operational performance against dairy/other sector benchmarks. Elements reviewed included line utilisation and performance, manning and labour costs, product yields and wastage plus other overheads such as energy, maintenance, etc.
The exercise identified significant benefits potential at each of the sites – these were subsequently delivered by the internal management team.
ROI FMCG Group
This client operated out of two manufacturing locations across the island. Faced with increasing market competition and rising internal operational costs, we were tasked with evaluating the costs, benefits and risks of rationalising operations to a single site.
This entailed developing capacity, manpower and logistics models to identify and understand impacts of the proposed change. In addition, we also developed detailed capex, redundancy and operating budgets to support delivery of the new model.
On the basis of this evaluation, the client decided to progress the proposed site closure – MDR were retained to project manage the subsequent implementation phase.