Food & Tobacco-104
The Situation:
The largest Americas flexible packaging company and a major manufacturer of pressure sensitive materials was closing two plants and relocating the equipment to a 3rd plant that was being expanded. During the transition they need to ensure there was no impact on customer delivery or service. They asked The Highland Group to support them by optimizing the processes in the expanded plant, preparing the staff, and managing the transition.
The Driver Goal:
- Transition the production of three plants to one expanded plants while maintaining the production and output levels of three plants with no impact on customer delivery or service
- Upgrade the skill levels of staff in the expanded plant to enable them to operate the newly installed equipment with no loss in production levels
- Upgrade the support function in the expanded plant to manage the increase in business with no negative impact on customers
Actions Taken:
- Developed production plans that insured continued delivery of product to customers during transition and relocation of equipment
- Coordinated and monitored physical relocation of the equipment
- Developed and implemented operator training programs for the new equipment at the expanded plant
- Developed organizational staffing models for the support functions in the expanded location to assist them with the expanded volume and duties
The Results:
- Consolidated plant operations with no loss of service to customers or customer complaints
- Relocated and Installed equipment ahead of the schedule
- Trained one hundred plus new employees and retrained existing employees with no adverse effects to sales, operations or customer service
- Exceeded production levels of three plants in the expanded plant within 90 days
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