Achieving Business Process Improvement Through the Development of a Lean Culture

Food and Beverage

Client Overview
Client Overview: The Irish arm of a multinational meat production group network experienced substantial internal competition to outperform international counterparts. They identified the need to gain a competitive advantage through improved quality, service level and reduced cost all of which can be acheived by developing a Lean culture.  

Challenges

• Requirement to outperform internal counterparts in cost, service level and quality
• Lack of flexibility to respond to customer requirements
• Absence of data driven decisions

Solution

• Used lean thinking & training to drive responsibility to the production line leaders
• Introduce 6S to engage all staff in the improvement activities.
• Implement PIT meetings to embed real time discussion on performance, issues and resolutions.

Results

• Business results have consistently achieved in a challenging market.
• Significant cost savings were achieved through implementation of lean projects.
• Strong support from client organisations due to increased transparency.

The operations team worked with LBSPartners to implement a lean culture with effective communication, flexibility to customer demands and data driven and timely decision making. Through this work a lean culture was established where everyone in the organisation supported the front line workers.

Improving Capacity and Product Yields Whilst Reducing Overtime in a Growing Dairy Processing Facility

Food and Beverage

Client Overview
Client Overview: An Irish-owned dairy production business, was facing issues in producing to demand without adding overtime to their resource costs. The management team sought to make improvements in their production capacity and increase the product yields while not increasing overtime.  

Challenges

Using tried and tested lean tools this company made significant improvements in process efficiency.

• Process mapping to identify root causes of yield issues.
• Introduce Daily Performance, Issues Targets (PIT) meetings
• Kaizen problem solving events.

Solution
LBS Partners implemented a Lean Transformation strategy, focusing on:

• Aligning production processes to ensure consistency and quality 
• Cutting operational costs through lean methods 
• Optimising resource use to boost productivity

Results

• 45% improvement in total production output (units/hr)
• Real-time communication, measurement and feedback on production line performance.
• Overtime eliminated and flexible work introduced to optimise labour

Through effective engagement with the production team significant improvements were seen in the production output.

Lean Transformation at Heineken

Food and Beverage

Client Overview
Heineken struggled with efficiency and production consistency. This hurt the leading company’s production and response to the market. 

Challenges

• Inconsistent production processes
• High operational costs
• Inefficient resource utilization

Solution
LBS Partners implemented a Lean Transformation strategy, focusing on:

• Aligning production processes to ensure consistency and quality 
• Cutting operational costs through lean methods 
• Optimising resource use to boost productivity

Results

• Achieved a 15% reduction in operational costs
• Improved production consistency and efficiency
• Enhanced resource use, increasing productivity

The Lean transformation helped Heineken streamline operations. It reduced costs and improved efficiency. This supported sustainable growth in the competitive brewing industry. 

Lean Plus Program in Cheese Production

HR Operations Optimisation

Client Overview
Top cheese producer Golden Dairy had issues with quality, costs, and efficiency in production.

Challenges

• Inconsistent product quality
• High operational costs
• Inefficient production processes

Solution
LBS Partners used a Lean Transformation strategy, to:

• Standardise production for consistent quality 
• Reduce operational costs with lean methods
• Streamline workflows to improve efficiency

Results

• Reduced operational costs by 20% 
• Improved product quality consistency
• Increased production efficiency by 25% 

The approach helped Golden Dairy cut costs, streamline processes, and keep quality. This ensures long-term growth in the competitive cheese production industry.