Case Study: Food Repackaging

Food Repackaging – low productivity issues, small business dealing with high volume

This business repackaged food and few other supermarket items; process was largely manual, few steps machine assisted. Business was struggling to make money due to poor productivity.

We were asked to review key assembly line methods. It was apparent that it lacked basic fundamentals which meant that product was handled and re-handled. One piece flow and economy of flow would help. I trained the key people covering lean, industrial engineering basics and use of videos to identify where motion being wasted.

After understanding concepts, the team changed the layout. Intermediate batching was cut back, and where practical one piece flow was implemented.

Operating on an Economy of Flow - rather than hoping for economies of scale - was the principle used to redefine method of working and avoid double handling.

Results – productivity improved by 9% in less than one week’s involvement.