Improving and Stabilizing Results Through Management System Implementation

The Business & The Challenge

A leading ingredient manufacturer operating in a high-demand market was experiencing significant operational instability due to:

• Frequent unplanned stops
• Focus on a key bottleneck area
• High turnover among operators and leadership
• Lack of process standardization

The core question:
How to stabilize and improve results with a strong management system?

Approach Details

To address this, Falconi implemented an integrated management framework across four dimensions:

1. Management Metrics and Tracking Tools

• OEE methodology implementation and target-setting
• Digitalized measurement and visualization of performance
• Application for real-time capture of downtime causes

2. Process Mapping and Training

• Standard revision and documentation
• Operator training programs
• Diagnosis of Operational Workflows

3. Operational Meetings and Problem Solving

• Daily and weekly meetings for team alignment
• Use of structured tools for deviation treatment
• Problem-solving training to empower teams

4. Leadership and Operator Routines

• Implementation of standard work and management routines
• Development of operational routines
• Creation of inspection routes and application of 5S

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Improvement Projects Executed

• Shift Handover Optimization
• Lunch Rotation Planning
• Equipment Setup Centerlining

Change Management Support

• Clear communication plan to ensure alignment
• Defined change agents and leadership coaching
• Recognition programs and celebration events to build engagement

Results Achieved

Metric                           Outcome

OEE                                +32% increase

Throughput                +20% increase

Process Variation     -72% reduction

A notable increase in average daily production, now performing with far greater consistency and significantly reduced deviation from control limits.

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Why It Worked

• Holistic integration of tools, training, and routines
• Empowerment of operators and leaders through clear roles and standards
• Constant performance visibility and targeted problem-solving

Conclusion

Falconi’s approach enabled this ingredient manufacturer to transform a fragile production environment into a stable, high-performing operation. With a 32% gain in OEE and major reductions in process variability, this case proves how a well-implemented management system can unlock sustainable performance improvements in even the most challenging operational conditions.

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