Case studiesCase study · Consumer products · Packaging lines

Line efficiency up 40%, and a site that adopted lean everywhere

A large consumer-goods manufacturer with high-speed packaging lines, after more output from the lines it already had.

Line efficiencyBefore: baselineafter: 40% higher

Process wasteBefore: baselineafter: 15% lower

After: losses measured and cut.

The numbers

Line efficiencyBefore: Baseline. After: 40% higher.

Process waste, three production linesBefore: Baseline. After: 15% lower.

+40%line efficiency

15%less process waste across three production lines

3production lines in the waste analysis

Site-widethe site adopted lean manufacturing after the analysis

Time on the packaging lines went to stops, changeovers and jams, and there was no single picture of which losses cost the most.

Measured the losses on three production lines and ranked them by the time and material they cost.
Used the Five Focusing Steps on the step that limits the line: get the most from it, and set the rest of the line to its pace.
Ran the improvement work with the plant’s own team on the floor.
Showed the results to site leadership, which then adopted lean manufacturing across the site.

Why it held. The waste analysis convinced the site to adopt lean manufacturing everywhere, so the work did not stop at three lines.

A one-week Diagnostic: where to pace the line and a go or no-go, or you don’t pay.