Optimizing Production Capacity and Enhancing On-Time Delivery

A prominent confectionery manufacturer found itself facing significant challenges in meeting the growing demand for one of its most popular products. Despite their best efforts, production capacity was falling short, creating bottlenecks and missed opportunities in the marketplace. To address the issue, HPS was brought in to identify inefficiencies within the manufacturing processes and implement solutions to improve throughput, allowing the company to better meet customer demand.

The HPS team conducted an in-depth, data-driven assessment of the entire production floor operation, engaging directly with leadership and key stakeholders across departments to identify bottlenecks, inefficiencies, and constraints that were limiting capacity and on-time delivery. Applying the Lean principle of Gemba “Go and See,” the team regularly visited the shop floor to observe operations firsthand and engage with employees, gaining valuable insights into the challenges and opportunities within the process. This collaborative approach not only pinpointed specific areas for improvement but also prioritized targeted solutions aimed at optimizing workflows, enhancing resource allocation, and streamlining key processes.

A data collection methodology was developed, and a Visual Factory with KPI boards was set up to track safety, quality, productivity, daily goals, and team updates. We applied the Lean principle of “Go and See” in our analysis, with leadership regularly visiting the shop floor to observe operations and engage with the team. This hands-on approach, combined with daily meetings at the KPI boards, improved communication, boosted engagement, and increased retention. Through targeted improvements, including reducing setup times, optimizing planning, and implementing standard work, throughput rates increased.

48% increase in production capacity
21% improvement to on-time delivery