This blog is part of an editorial series written by Jeremy Praud, Head of UK & Europe.
This is now my fourth blog in the ‘Lean Audits for FMCGs’ series. If you’d like to start at the beginning, click here.
Otherwise, lets look at two key tools that are missing from the ‘Classic Lean’ Toolkit that would deliver significant value to FMCGs, an area of focus that doesn’t belong, and one of the greatest benefits of the M&S Lean Audit Framework.
Debottlenecking is missing – yet has fastest impact on your bottom line
The major tool missing from Classic Lean that is of tremendous value within FMCG is debottlenecking theory – sometimes called the Theory of Constraints (TOC). Pioneered by Eli Goldratt in the book “The Goal”, debottlenecking methodologies can be used to optimise line performance, and give a clear set of tactics to deliver improvement.
The average FMCG manufacturing line has approximately 9 processes. This is many fewer than a car line – and this difference is the key reason why constraint theory doesn’t appear in the classic Lean Toolkit. However, as a tool used to optimise speed, line control, and accumulation, it has one of the fastest impacts to the bottom line you can hope to achieve.
Improvement Systems is missing – yet critical to sustain improvement
Good leadership and management processes are of course common across industries. The M&S audit does a good job on most of these. If there’s one thing the audit is light on though, it’s ensuring the right reporting is delivered easily from the right kind of measurement systems. KPI’s are taken for granted within the audit – but all too often FMCG factories struggle with the accuracy of information. Ensuring your measurement system is telling you to work on the right things, not the wrong things, is of critical importance and should be high on your priority list.
Supplier Relationships – not relevant for most FMCGs
Lean Audits often prioritise focus on Supplier Relationships. For FMCG manufacturers, this requires leverage of the buyer on the supplier – and whilst this holds true in some supplier relationships, there are many where it does not.
The large enterprises have identified this, and in many instances are already trying to mimic the tactics used on them for so many years by the retailers. Whether the relationships being mimicked could be called compatible with “Lean” however is a different question.
The purpose of the Lean Audit framework should be to help you achieve a better cost to manufacture. If you are not a large enterprise, move Supplier Relations lower on list of priorities than other activity.
Improvement Champions – the real win for FMCGs
Finally, one of the greatest benefits the M&S Lean Framework will bring is the focus on having an improvement champion/manager. The legacy of a half a century of quality audits is that the requirement for a quality department is no longer questioned. The real win will be if Lean Audits help businesses to understand that whilst continuous improvement, like quality, is everyone’s responsibility – Improvement Champions are the key to ensuring the processes are working, running CI workshops, and offering training and support With Improvement Champions in place, we can look forward to a continual improvement in manufacturing efficiencies, reduction in waste, and ever improving manufacturing cost per unit.
Next time I’ll be looking at how to make Lean work in FMCG. And to hear more on this subject from us, retailer M&S, and supplier Greencore – register for this Food Manufacture webinar.