Overcoming production challenges to meet crucial summer volume demands
Britvic PLC, a leading British beverage manufacturer, faces constant pressure to optimize production capacity and meet market demands. Can volume is a critical success factor, and unlocking capacity in this area is crucial.
Delighting their customers with summer beverages and therefore volume is a crucial element in the ongoing success of Britvic’s operations. Britvic reached out to Lineview to help them meet their summer volume demand with existing infrastructure.
Meeting market demands and gaining an empowered team
Lineview partnered with Britvic to implement a two-week deep dive into line balancing optimisation at the Rugby facility. Building from an initial audit using the ‘5 Levels of Control’ line balancing methods, operational experts worked with Britvic’s team to achieve Perfect Flow. Lineview’s proven line balancing template identifies the gap between the current state and perfect conditions. The actions are then defined, and the potential savings are calculated.
By combining expert training, proven methodology, and collaborative implementation, Lineview helped Britvic unlock significant production capacity and empowered Britvic’s team to drive continuous improvement, ultimately gaining a competitive edge in the beverage market.
Methodology Deployment
Lineview’s proven LBO methodology was deployed, focusing on improving control, accumulation, speeds, start-up, and run-out times across the can lines.
Expert Training and Collaborative Implementation
Lineview’s industry experts trained eight Britvic team members in the Line Balancing Optimisation (LBO) methodology while closely collaborating with Britvic’s controls engineering team to implement practical line improvements.
“I’m hugely impressed with this intervention. We’ve unlocked significant capacity for our plant and reduced the impact of minor stoppages on our production lines. Most importantly, we’ve equipped our people to be able to go hunt down these opportunities throughout our business.” - Paramjeet Pahdi, Rugby Site Director, Britvic PLC
Unlocked hidden capacity to drive summer volume
Britvic’s partnership with Lineview helped them drive the summer volume successfully by unlocking the hidden potential. The LBO initiative unlocked £5.4M additional capacity, directly impacting Britvic’s bottom line.
Empowered and capable team The trained Britvic team is now equipped to identify and implement LBO opportunities across the entire organization extending the program to other manufacturing sites of Britvic.
Sustainable improvement
The project instilled an understanding of LBO as an ongoing process, ensuring continuous improvement and maintenance of production efficiency.
£2.5M in further potential identified
Further analysis revealed an additional £2.5M in potential capacity gains through further control optimisation.
