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New Manufacturing Technology

"Breaking these constraints enabled Emig to introduce an industry changing process for a new customer, securing 3 Million euro EBITDA per annum for six years" - David Wallace, Finance Director, Emig GmbH


Industry

Emig - soft drinks bottling

Support Level

1 consultant, 3 months

Objective

Secure a step increase in efficiency, in order to be able to contract pack a new customer’s volume; solve technical and quality issues related to full sleeve bottling

Results

  • €3 million profit (EBITDA) per annum
  • Efficiency improved by over 45 % within 4 months and by 75 % within 12 months

Why did this manufacturer join forces with chartwell?

An existing UK client asked Chartwell to assess capacity and help improve a critical contract bottling process.  Productivity needed to ramp up quickly, following a new contract packaging deal with a US based customer.  However, there were unresolved technological constraints with a new full sleeve format on the exterior of the bottle, and massive pressure to boost capacity before the peak season and new sales arrived.

Emig has a highly motivated leadership team who were working hard to improve both the throughput and quality of a new sleeving operation.  Chartwell coached the team to understand and realise the true potential of the line.

Results of the 3 month project

  • Output increased by 45 %
  • Contract secured with EBITDA of €3 million per annum
  • Team continued to increase output by 75 % within 1 year

Examples of Project work

What were the technical issues limiting the output of the sleeving process?

USE OF ACCUMULATION:

Combination of short stops, lack of over speed and design of control philosophy mean filler stops frequently.


APPLYING THE SLEEVE:

Technical challenge of applying a full sleeve to a cold bottle covered in condensation.


SHRINKING THE SLEEVE:

Process parameters not well understood; they are adjusted differently by each operator and some view the shrink tunnel as an apparent “black box”.

What actions were taken in solving these technical constraints?

ACTION:

The main technical challenges for the team to solve were to control sleeve application onto the bottle at higher speed and at the same time understand exactly what was happening inside the shrink tunnel, so that the tunnel process parameters could be optimised.

Chartwell trained the team in Fault Tree Modelling, a tried and tested technique for solving complex problems with multiple interrelated root causes. Through fully understanding the key parameters, the team were able to gain control of the process.