Eat Just

A plant-based protein company was founded in 2011 as a food company specializing in plant-based products. The company has experienced rapid growth globally, standing out for its innovative and sustainable approach. The acquisition of a plant in the United States has been instrumental in its transformation to Manufacturing 4.0, which has improved operational efficiency to meet growing market demand.

London Consulting Group collaborated with the organization to optimize its operations through advanced tools such as Power BI and CMMS (Computerized Maintenance Management System). This collaboration not only increased operational efficiency, but also strengthened the company's leadership, positioning it to successfully meet the challenges of the manufacturing industry.

CHALLENGE

OVERCOMING BARRIERS TO TRANSFORM INDUSTRIAL OPERATIONS

The plant-based protein company was looking to consolidate itself as a Manufacturing 4.0 organization, facing the challenge of institutionalizing processes, improving collaboration between areas and reducing costs. These challenges included establishing a data-driven continuous improvement model and strengthening plant leadership.

Institutionalization of processes: Evolve from a family business to an organization with 4.0 manufacturing practices, implementing management systems and optimizing the use of ERP and CMMS for new investment projects (CAPEX).
Governance model: Formalize a data-driven continuous improvement model for more efficient decision making.
Leadership development: Strengthen plant leadership and increase team accountability.
Collaboration: Improve cohesion between corporate and plant functions, integrating new managers.
Cost reduction: Optimize conversion costs to increase competitiveness.

STRATEGIC OBJECTIVES

Reduce cycle time by 5% by improving equipment availability and increasing production.
Increase product yield by 1.8% by better controlling process parameters.
Improve the proportion of preventive maintenance to 47% versus 53% of corrective maintenance.

OPERATIONAL AND TECHNOLOGICAL EXCELLENCE OBJECTIVES

Standardize operations to ensure consistency in production.
Use business intelligence for strategic decisions.
Maximize the use of CMMS and digitize manual processes.

ORGANIZATIONAL DEVELOPMENT AND CHANGE MANAGEMENT OBJECTIVES

Formalize processes and move to world-class manufacturing.
Training in management systems to optimize CAPEX projects.
Develop leaders and foster a culture of continuous improvement.

IMPLEMENTATION

STANDARDIZATION AND LEADERSHIP: IMPLEMENTING KEY PROCESSES TO TRANSFORM PRODUCTION

London Consulting Group identified opportunities for improvement and standardized key processes in the plant-based protein company. The following highlights the main initiatives and key moments that made this project successful:

Identification of opportunities through interviews and in-depth analysis.
Implementation of crash plans to standardize processes, optimize roles and improve OEE (Overall Equipment Effectiveness).
Use of CMMS for preventive maintenance and equipment optimization.
Leadership development and training with a focus on continuous improvement.
Creation of Power BI dashboards and an effective management model to improve decision making and communication.
Implementation of standardized scaling and monitoring protocols with applications.
CMMS integration with Power BI for deeper analysis and inventory control.
Establishment of SOPs (Standard Operating Procedures) and audits to ensure the sustainability of the new processes.

OPERATIONAL AND TECHNOLOGICAL EXCELLENCE - PRODUCTION

Implementation of continuous improvement through the PDCA cycle, increasing efficiency and reducing downtime by 14%.
Use Power BI to analyze and track key KPIs analyze and act on key KPIs such as OEE and production performance.
Documentation of new processes to facilitate adoption by operational personnel.

OPERATIONAL AND TECHNOLOGICAL EXCELLENCE - MAINTENANCE:

Configuration and optimization of the CMMS, moving from corrective to preventive maintenance.
Master data structuring and KPI design for maintenance.
Documentation of processes to improve the adoption of new tools.

ORGANIZATIONAL DEVELOPMENT AND CHANGE MANAGEMENT:

Improved communication between leaders and managers through group dynamics.
Increased willingness to change and accountability for project results.
Implementation of an individual development plan to improve leadership competencies and skills.

TESTIMONIALS

STORIES OF TRANSFORMATION

"With the help of LONDON CONSULTING GROUP, our Operations and Maintenance departments underwent a redesign of their processes and procedures that optimized our production chain. Their systematic approach and Change Management methodology, which included man or shoulder implementation with our floor staff, ensured a quick acceptance by our collaborators, a spirit of continuous improvement and that the results will last in the long term."

Evolving processes to drive

EAT JUST