Uncovering New Ways to Improve Yield, Lean in Food & Beverage Manufacturing

F&B companies can experience unprecedented growth in yield by going beyond established continuous improvement processes.

TBM Consulting Group authors have found it possible to produce an 18 to 25% improvement in yield on a repeatable basis, using an innovative combination of time-honored methods and statistical analysis.

Huge gains in yield have been achieved through Lean Manufacturing, Six Sigma and Kaizen, so much that it may seem that no more can be done, particularly in waste-intensive, fast-food and beverage industry where efficiency gurus seem to have wrung out every increase possible. We believe there is still room to achieve more ROI from yield improvement. Organizations that embrace these new approaches are often among the best-run companies, outperforming the industrial averages and their nearest competitors.

The best approach, whether Kaizen, Lean Manufacturing or Six Sigma, really depends on the specialized problem you’re trying to solve. Kaizen is usually about individuals or teams identifying and fixing a problem, while Lean is about improving process speed and quality by reducing waste, and Sigma seeks to optimize output, stability, and accuracy. We have been looking at an approach that fine tunes the mix, if you will, of Sigma and Kaizen. 

By focusing on a select few process parameters with the most impact on waste production, and adjusting these based on statistical analysis and practical insights from frontline operators, companies have seen dramatic reductions in waste and enhancements in yield. This approach not only ensures ongoing enhancements but also fosters a culture of efficiency and responsiveness that aligns with strategic goals for long-term growth and competitiveness.

Read more on this article, including examples include significant savings from reduced ingredient loss and scrap waste, achieved through a combination of operator-focused problem-solving and statistical analysis.