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We are a global management consultancy that delivers exceptional outcomes and sustainable change
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There is a growing demand for spices, herbs and other types of seasonings, driven primarily by consumer demand for authentic ingredients and the increasing popularity of ethnic flavors.
According to the report ‘Spices and Seasonings Market, 2021 – 2028’, the global spices market size was US$17.12 billion in 2020 and is expected to grow to US$24.23 billion by 2028 at a compound annual growth rate (CAGR) of 2.55% over the forecast period.
The global network of spice producers is not only a culinary necessity, but also the backbone of the food manufacturing industry, enriching our palates and plates, and supporting livelihoods around the world.
Our client is one of the world’s largest producers of whole, powdered and processed spices manufactured in accordance with global food safety standards to ensure quality and taste.
The company engaged Greaux Consulting to help improve throughput, reduce repetitive failures, and design and install operational scorecards. Key deliverables from the project include:
The project started with Greaux Consulting Focus Process, where we identified several key issues that were limiting the company’s ability to meet its installed capacity. Our analysis revealed that there was inadequate monitoring of output at hourly and shift levels, poor control of planned and unplanned downtime, poor data logging, and a lack of a target-setting process.
People-related challenges were also identified, such as plant operators being unaware of the company’s expectations, inappropriate manpower utilization, and poor attendance during night shifts.
Focused discussions and observational studies were then conducted with key process owners to gain insight into day-to-day issues, managerial control, and problem-solving processes from operator to production in-charge levels.
It was suggested that the introduction of checks and controls, including system elements, could guide people’s behavior to achieve the desired level of output. Additional opportunities were identified in areas such as order planning and scheduling, dispatch planning, order pipeline management, order profitability, review mechanisms, and meeting effectiveness.
Developing and implementing optimized management control systems and processes for sales.
Developing standardized practices.
Delivering a seamless customer experience, from initial contact through the onboarding process to day-to-day customer maintenance and support.
Improving communication and process interfaces with other functional areas such as production, planning and quality, research and development, and back office.
1. The following measures have been implemented to improve throughput:
2. The following measures have been implemented to increase the operating time:
A cross-functional Management Action Team (MAT) with participants from all key functions was established to manage these initiatives and ensure the involvement of all key process owners.
Strategic Integration Meeting (SIM)
A SIM meeting was held in week seven of the project, and the team developed a time-bound implementation roadmap for improvement. The roadmap was designed to address outstanding issues and create a culture of continuous improvement.
Key initiatives
System elements were implemented to address order planning and scheduling. The team also institutionalized a formal structure to review performance and plan for the next period.
A digital transformation program was initiated to improve the availability of real-time production data and expedite decision-making. Data collection via handheld devices was designed to enable data transfer to the Enterprise Resource Planning (ERP) system.
To address behavioral and cultural change in the workplace, key process owners were trained in various concepts that could help improve their skills and attitudes.
Shipping increased by
Throughput improved by
Inventory reduced by
Conversion costs reduced by
*We have intentionally omitted client-specific details to maintain strict confidentiality.
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