Food Co. is losing out to its competitors
Six Sigma and Lean priniciples used to improve plant performance
Implement six critical initiatives to improve plant capacity and equipment effectiveness
15% cost savings, improved capacity by 30% and increased equipment effectiveness by 25%

Lean Six Sigma improves plant performance and cuts costs
Problem:

Food Co. is losing market share to strong competitors and suffering from slowing growth in primary channels. To remain competitive, the client must:

  • Improve manufacturing facilities to reduce cost and increase capacity, and
  • Invest in innovations needed for growth and competitiveness

The client asked Bain to address the following key questions: 

  • Can capacity be increased in existing plants?  How much, and where?
  • Can cost per ton be reduced on existing lines?
  • Can enough cash be freed up from operations to fund investments in innovations?