Sugar Industry
Mission
Due to the EU sugar market regulation, our customer expected volume and price reductions. The production system of a leading sugar producer should be optimized to increase productivity by a double-digit range. Another task was to implement a new concept for material management and distribution centers to meet future challenges in reducing food distribution, inventory and transport costs.
Solution and Work Process
Efficient prozesses and structures
Conversion of a functional organization into a process organization
Integration of maintenance and repair staff into the service concept of the production lines
Changeover to teamwork and joint leadership and performance concepts
Planning and performance control of the plant
Introduction of a new planning and control of production including key figure-based MES
Introduction of new team and working time models including monitoring and performance reporting
Integrated material management and storage concept
Conception of an integrated material management concept with the aim of centralizing the warehouse
Approaches and concepts for a central logistics center west
Personnel structure and development
Definition and implementation of a comprehensive qualification matrix
Conception of the regulations for new working time models and structures
Results
The productivity increases realized in the plant are in the double-digit range. The inventory, storage and transport costs were also greatly reduced. A logistics center was realized.
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The complexity of customized solutions in mechanical engineering and plant construction is continuously increasing. Highly qualified employees are working across the entire value chain to provide the optimum service, sometimes requiring high stocks.
Precise planning and delivery service on time allow reduced stocks and increased productivity. Real-time capability accelerates cooperation and communication to control complexity and to react optimal to unforseen events. Small batch sizes production supports a better flow of work and material, an intelligent organization and cost leadership.
