Addo Food Group
~40% throughput increase
£350m turnover bakery producing savoury pies and pastries for UK supermarkets.
- Increased output of targeted lines by approximately 40%
- 80% reduction in giveaway and line wastage
- Cycle-time analysis to increase bottleneck process speed
- Embedded a culture of data-led continuous improvement
- Problem-solving training for operators and engineers
Oscar Mayer UK
~15% output increase
Leading ready meal supplier to all major UK supermarkets.
- Designed and implemented bespoke manufacturing data collection system, increasing output by approximately 15%
- Hybrid of automatic timing capture and manual reason overrides to boost data actionability and operator engagement
- Integrated troubleshooting tools to aid line-operator triage, reducing lost time due to shift variation by 50%
- Eliminated lost time due to slow running and incorrect settings by 90% via cross-site visibility
- Noticeable change in site culture from "things will never change, no one listens" to improved morale and collaboration
Embecta
2.5% OEE boost via buffer optimisation
Global manufacturer of disposable insulin care products.
- Cross-site (Ireland/China) comparison project to understand performance differences and raise OEE by 10% over 12 months
- Analytics support to build digital twin of complex, highly automated production lines
- Optimisation of accumulation and buffers to boost OEE by 2.5% with small capex investment
- Worked with OEM to suggest reliability improvements for next-generation lines
- Developed predictive maintenance analysis using existing data capture, preventing low-frequency high-impact downtimes
Becton Dickinson
Continuous improvement team built from zero
Global med-tech manufacturer of testing devices including blood test kits.
- Complex, strongly coupled manufacturing lines battling medical product quality standards and equipment reliability
- Problem-solving and continuous improvement training at all levels, from line operators to senior management
- Data analysis and live reporting giving clarity of financial impact of all drivers of lost time
- Marked reduction in repeat issues, enabling a cultural shift away from firefighting
- Engineers empowered to take the time to solve issues to zero and for good
Warburtons
8% reduction in distribution miles
Britain's 2nd largest bread and morning goods bakery with its own direct-to-store distribution network.
- 8% reduction in miles driven and driving shifts required amid a national driver shortage
- Developed original distribution optimisation algorithms after the RFQ was rejected by all 9 software suppliers and deemed too complex
- System integration work to enable faster order processing
M&S Food
£20m saved through stock loss reduction
£5bn revenue premium British food retailer.
- Data analysis and system integration that aided a 30% reduction in stock loss
- £20m saved across food waste and lost sales
- Enabled targeted and testable process change experiments across stores and warehousing
Iceland
Novel ranging and customer profiling
£2.5bn revenue discount supermarket specialising in frozen and chilled goods.
- Novel data-science analysis of customer purchases to identify product relationships, customer profiles, and unmet customer needs
- Enabled data-led discussions with suppliers where Iceland could steer NPD to fit ranging gaps