Enhancing Quality Control for a Beverage Dispenser Equipment Manufacturer

THE CLIENT

A leading manufacturer of industrial-grade beverage dispenser equipment based in the UK, grappling with challenges in manufacturing equipment maintenance across its Quality Control (QC) system.

THE CHALLENGE

Our Enterprise Health Check assessment pinpointed inadequate manufacturing equipment maintenance within the QC system, stemming from a lack of regular maintenance, reliance on outdated equipment, and absence of equipment calibration.

ASSESSMENT

Lead Measures

Maintenance Schedule Adherence: Only 50% adherence to planned schedules.
Preventive Maintenance Initiatives: 30% of equipment without preventive maintenance.
Equipment Operator Training Programs: 40% of operators untrained.
Equipment Upgrade Initiatives: 20% of equipment outdated.
Capital Investment Planning: Mere 25% of required capital investments made.
Calibration Schedule Adherence: 60% non-adherence to calibration schedules.

Lag Measures

Equipment Uptime: Average uptime of 70%.
Quality Control Pass Rate: Dropped to 80% from 95%.
Product Return Rate: Increased to 10% from 2%.
Equipment Performance: Declined by 15% over the previous year.

SOLUTIONS

Implement Regular Maintenance

Formulate a comprehensive maintenance schedule.
Conduct staff training on adherence and monitoring.
Initiate regular audits for compliance.

Upgrade Outdated Equipment

Identify and prioritize outdated equipment.
Allocate capital investment for necessary upgrades.
Continuously monitor performance improvements.

Enhanced Equipment Calibration

Establish a stringent calibration schedule.
Train operators on calibration procedures.
Launch preventive maintenance initiatives.

RESULTS

Improved Maintenance Schedule Adherence: By 40%, enhancing equipment uptime to 90%.
Increased Preventive Maintenance: By 50%, reducing breakdowns and increasing equipment performance by 20%.
Enhanced Operator Training: 100% of operators trained, improving quality control pass rate to 95%.
Upgraded Equipment: 100% of outdated equipment replaced, reducing product return rate to 3%.
Improved Calibration Adherence: By 30%, leading to a 10% increase in overall equipment performance.

CONCLUSION

This case study illustrates the transformative power of targeted interventions in manufacturing equipment maintenance. By meticulously addressing the specific challenges faced by the industrial-grade beverage dispenser equipment manufacturer, the company was able to significantly enhance its quality control system. The experience highlights the critical role of a thorough assessment, data-driven insights, and bespoke strategies in achieving operational excellence, leading to tangible improvements in equipment performance, quality control, and customer satisfaction.

Note: The above values are estimated variables and are subject to change depending on the scope, volume, complexity, and unique circumstances of each client.