$700M
Annual revenue
Plant Turnaround Boosts OEE for a Shelf-Stable Juice Manufacturer: Restoring Operational Excellence and Workforce Stability Through Lean and TPM Practices
Industry: Food & Beverage
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: People and Organization
Our Client
A $700M North American beverage manufacturer in the shelf-stable juice segment.
3
Production lines in shelf-stable juice manufacturing
The Challenge
The company faced declining performance and operational instability, further worsened by COVID-19 impacts.
- Turnover rate over 80% undermining production stability.
- OEE below 30% across three production lines.
- Chronic yield losses due to poor equipment reliability and maintenance.
Real Results Achieved Together
The turnaround program rapidly stabilized operations and delivered measurable performance gains across productivity, cost, and workforce metrics.
+25%
Improvement in hourly beverage throughput
$5M
EBIT gain thanks to the +20 OEE points within six months
$8M
CapEx avoided through operational optimization
Transformation Impact
By combining lean methods, TPM, and reliability-centered maintenance, the client achieved breakthrough improvements in asset performance, labor stability, and profitability while avoiding significant capital investments.
- 85 positions filled and sustained staffing stability (<10 openings for 18 months)
- 10% reduction in cost per fluid ounce filled
- 40% reduction in mechanical downtime
- 30% increase in mean time between failures
Our Approach
EFESO executed a comprehensive plant turnaround program centered on improving asset reliability, workforce stability, and operational efficiency through Lean, TPM, and RCM principles.
Key initiatives included:
- Maintenance transformation via TPM and Reliability Centered Maintenance (RCM), supported by preventive maintenance plans.
- Staffing alignment with plant needs and creation of external back-up services for workforce flexibility.
- Critical spare parts optimization and on-demand equipment back-ups to minimize downtime.
- Hiring process redesign reducing cycle time from 5–25 days to 90 minutes, enabling competitiveness with nearby employers.
- Supervisor Lean training to build problem-solving capabilities and waste identification skills.
- Execution of 18 Blitz Kaizens to improve material flow, shift hand-offs, and changeovers.
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Facing Similar Performance and Workforce Challenges?
- Need to restore operational reliability and throughput.
- Want to strengthen workforce stability and engagement.
- Seeking to boost OEE through Lean and TPM practices.
- Aiming to avoid capital expense through performance optimization.
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