Download A PDF Copy Of This Case Study Here!
Vitamin Production Wheels
The Highlights
A leading nutraceutical company sought to optimize packing asset utilization and production efficiency. Zinata introduced “Product Wheel” scheduling, which optimized order rotation through bottle size variants to minimize changeover downtime and improve throughput. Results included an impressive 12-point increase in OEE, a 34% throughput surge, meeting demand with two fewer lines, and $1.5 million in annual labor savings. Zinata provided Excel tools, training, and cross-departmental collaboration. They iteratively enhanced tools, integrating them with the ERP for future planning. Standardized wheel patterns streamlined operations, improving efficiency and enabling better supply chain and labor planning.
The Headlines
- 12 Points: Increase in OEE
- 34%: Increase in Throughput
- $1.5 Million: Annual Labor Savings
The Details
Situation
The client, a large nutraceutical company, was facing intense competitive cost pressures and relatively unproductive assets. Overall Equipment Effectiveness (OEE) at a key packaging plant averaged less than 40%, far below industry benchmarks. It was imperative to significantly increase OEE and improve line throughput to satisfy all customer orders.
Problem
- Low Overall Equipment Effectiveness (OEE)
- Inefficient product changeovers
- Lack of optimized scheduling methodology
- Excessive and time-consuming adjustments after product changes
- Disconnect between scheduling and change requirements
Solution
Zinata implemented “Product Wheel” scheduling to optimize product frequency and sequencing, minimizing changeovers and allocating bottle sizes to reduce rail changes. They increased run size for low-demand products and developed Excel-based tools for scheduling. Training and support were provided, involving cross-functional teams to improve management parameters. The product wheel tools were continuously enhanced and integrated with ERP for future planning.
Benefits
- Improved customer service
- Ability to meet demand with two fewer packing lines
- Improved systems view of product line-up
- Better supply chain and labor crew planning
- Predictability of future product needs
Results
Zinata’s introduction of “Product Wheel” scheduling has significantly transformed the operational efficiency of a leading nutraceutical company. By optimizing order rotation and minimizing changeover downtime, the company achieved a 12-point increase in OEE and a 34% surge in throughput, all while meeting demand with fewer packing lines and realizing substantial labor savings. This comprehensive approach not only improved immediate production metrics but also enhanced long-term planning and efficiency through ERP integration. The success of this initiative demonstrates the profound impact of strategic scheduling and cross-departmental collaboration in the nutraceutical manufacturing industry.
