Kilkenny Nutritional specialises in nutraceutical products for the infant, functional beverages and food for special medical purposes sectors.
Kilkenny Nutritional Beverage Company is based in Piltown, Co. Kilkenny and was established in 1988. Kilkenny Nutritional is a dedicated hot fill facility offering ambient stable, preservative free, clean label products.
Lean Transform Objectives
The key objective of the program was to improve the competitive advantage of the company through the implementation of lean initiatives and associated projects.
These objectives were delivered through the implementation of these projects
- Lean awareness training and core behaviours roll-out to all staff
- The introduction of Performance Management.
- KPI upgrade system for filling times.
- Management Development Training.
- Waste and Effluent Reduction.
- Maintenance Systems upgrade.
The objectives of the project were to increase OEE to a target of 85% on the PET lines and 75% on the pouch systems.
There was also a significant challenge around yield on the pouch systems for our medical foods production with waste factors running at 12%.
To achieve these objectives, a number of key initiatives were put in place.
- Workplace Organisation — rollout of A frame change parts and a detailed change parts programme
- Significant Investment in the alteration of the pouch line process to improve yields and to maximise quality. This investment has led to a 6% improvement in yield.
- Standard work — implementation of front line asset core by operators.
- Implementation of an upgraded preventive maintenance system for the PET and pouch filling lines.
The company also introduced performance management for key management and implemented a core behaviours review for all employees.
This was to ensure that the right behaviours are aligned to job needs to drive the required performance.
The lean transform programme has been very successful in Kilkenny Nutritional. The core projects implemented such as standard work and KPI review has increased operational efficiency in 2016 to 79.3% from 65% in 2014/15 on the PET bottle filling lines and from 70% 2014/15 on the pouch lines to 76.3%.