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  • TPM – Theory of Operation
    • A TPM Success Story in The Food & Beverage Industry

Commercial Foods Group

PROBLEM

Excessive working capital inventories in the distribution supply chain were creating excess operating costs within the warehousing and distribution functions of the Company

Balancing production, output capacity with sales demand was difficult under the current legacy systems which limited production scheduling and capacity correlations to demand.

APPROACH

Perform a process and order fulfillment analysis to understand optimization methods to balance production capacity and product mix with inventory and customer order demand.  From the analysis an alternative systems strategy was formulated for production scheduling to reduce warehouse inventory investment and maintain order service.

J & A International Lean TPM Client ConAgra Foods

SOLUTION

Provide a system roadmap that integrated production scheduling with order demand to optimize inventory and service across the regional distribution site network.

Model the production capacity capability and product mix changeovers to optimize plant facility utilization and distribution inventory replenishment.

IMPACTS

Developed a corporate program and strategy to take the Company to a:

–30% reduction in distribution inventory

–20% reduction in distribution cost

–Increased plant OEE utilization to more than 90%

 

Total Annual Savings:

$500,000

SUCCESS STORIES

  • A TPM Success Story in The Food & Beverage Industry
  • DAIRY
  • FRESH VEGETABLES
  • JUICE PACKAGING LINE
  • COCA-COLA BOTTLING
  • PASTA
  • MEAT PACKAGING
  • COMMERCIAL FOODS GROUP
  • EDWARDS LIFE SCIENCES
  • PHARMACEUTICAL
  • ENERGY OPTIMIZATION
  • HEALTH
  • AUTOMOTIVE PAINT
  • US AIR FORCE
  • PARKER
  • EMERSON ELECTRIC – HOUSTON
  • EMERSON ELECTRIC – CHINA
  • A & E AUTO ELECTRIC
  • HEXAGON
  • STANADYNE

Published By Our Team:

The Need for Trust in Lean Transformation - by Keith Johnson

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© 2025 · J & A International, Inc. - LEAN TOC

  • A TPM Success Story in The Food & Beverage Industry
  • DAIRY
  • FRESH VEGETABLES
  • JUICE PACKAGING LINE
  • COCA-COLA BOTTLING
  • PASTA
  • MEAT PACKAGING
  • COMMERCIAL FOODS GROUP
  • EDWARDS LIFE SCIENCES
  • PHARMACEUTICAL
  • ENERGY OPTIMIZATION
  • HEALTH
  • AUTOMOTIVE PAINT
  • US AIR FORCE
  • PARKER
  • EMERSON ELECTRIC – HOUSTON
  • EMERSON ELECTRIC – CHINA
  • A & E AUTO ELECTRIC
  • HEXAGON
  • STANADYNE