Project Summaries

Rolling Out More Capacity

Rolling Out More Capacity

Project Details

Client:

Van’s Kitchen

Business Area:

Supply Chain Operations

Opportunity:

Expand production capacity within an existing plant footprint in order to support a new customer who ordered 20 million eggrolls

Approach:

Started with a single 2-day Kaizen event to analyze the value stream, and eventually repositioned the entire production line

  • Identified a major product flow opportunity in the manufacturing process, and developed a flexible product conveying concept to optimize flow
  • Created load and capacity models, then designed a new facility layout and product flow
  • Supported the purchase and installation of new production packing machines and product handling conveyors
  • Facilitated change management efforts as new equipment installation, roles, and production schedules came together

Results:

  • Over 50% increase in annual capacity – same plant, same shifts, millions more eggrolls!
  • Improved ability to respond to more customers in less time (product mix increase of 50%)
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