As part of the Growth by Choice program, a cross-departmental team of Innodis employees was trained to work on a specific project. They were tasked with improving the performance of the company’s two main production lines for yoghurt and ice cream.
Innodis’ dairy production aims to produce the highest quality products, within the shortest lead times and at the lowest cost. Optimal use of resources is therefore needed. The team had to assess the current process and measure production losses. Their in-depth analysis identified the main production issues and highlighted the need for changes and improvement to yogurt production and its specific processes. The Ishikawa approach (or Fishbone Analysis) was used to observe the process and propose improvement actions. Data was collected to identify the root causes of the losses, and specific improvements were then proposed to reduce waste at each stage of the production line. Using their combined engineering skills and experience, they
were able to make useful recommendations that were then implemented. This included the addition of powerful new pumps, redesigning certain production lines, and implementing improved processes to save time and reduce waste. Net yield improved by 4%, increasing from 86% to 90% for the 2019 financial year. This represents a potential savings of Rs 3 million per annum.
The improved work system has now been fully implemented, and the team meets weekly to discuss gaps and review new work plans. They are already planning their next project, which will focus on adapting the CAF (“Compact Automatic Functional”) filling machine, for the new Greek yoghurt packaging.