Global food retail sales exceed $4 trillion per year. The industry has evolved significantly over the last two decades as a result of technological advances, keeping up with the rising demand for convenience foods. This industry demands more packaging to ensure safe, fresh, and easy-to-use products. Demand for higher-quality foods in greater quantities drives several other industries, including convenience stores, supermarkets, hypermarkets, and gas stations with grocery sections. In this article, we will talk about the How Important Operational Excellence in FMCG.
An increasing global population and a shift toward convenience food continue to propel the industry forward, with Asia-Pacific accounting for 45 percent of the overall market. Food culture is changing, which means that different tastes are increasing demand for ethnic foods and newer formats like microwaveable food products. As a consumer, convenience is critical.
Quality and quantity both are crucial to the food processing industry. Multiple challenges limit the production and delivery of the items due to inefficient systems and manufacturing processes.
The key challenges the food industry faces worldwide are:
- Low production output
- High level of inventory
- Frequent Quality issues
- High Wastage
- Poor workplace management
- High changeover time
- Machine inefficiency
- Low manpower productivity
Faber Infinite Consulting’s expertise in implementing improvement tools for Food Industry has delivered excellent results for clients in different countries. One of the renowned clients from Africa that produces maize and soya-based food products had engaged with us for shifting their manufacturing unit to a new place. Team Faber has assisted them by remodeling and facilitating a new layout design for their new facility with our proven and unique Lean Facility Design© (LFD) framework. The approach taken by Faber’s expert consultants included Value Stream Mapping, design flow, capacity planning, Manpower planning, equipment management, visual management, material handling, and more.
The tangible benefits delivered by implementing our well researched, copyrighted tool,
Lean Facility design is:
- 36% increase in Production
- 33% reduction in Throughput Time
- 34% reduction in Inventory Cost
- 42% improvement in Productivity
- 17% Space Optimization
Our quest for improvement projects in Food Industry continues to even sales excellence. Our project on increasing sales for one of our clients from Zambia has given us the chance to guide the client team productively by engaging in training and analysis. Both, Team Faber assisted the client to prepare annual budgets, reviewed and restructured the organization with performance management tools, and also introduced them to new markets and product penetration. The improvement numbers have helped us to determine more than 80% growth in sales for our valuable client.
One of the well-known clients from the food processing industry in India, also engaged with the Faber Infinite Consulting in the success story race. We identified key tangible benefits delivered for the client which improved the overall productivity of the manufacturing unit, they are:
- 30% improvement in manpower productivity
- 35% Reduction in Changeover time
- 20% Reduction in Wastage while packaging
- Released nearly $2 million in working capital through inventory management
Written by Faber Aleena & Compiled by Faber Mayuri
