SUCCESS STORY
45% increase in productivity
Post-Merger Operations Integration Through Total Productive Maintenance (TPM)
- How Henkan’s structured approach led to measurable, sustainable outcomes
Our Impact
Short-term impact
- ~24% increase in productivity
- Operational performance index (OPI) improved from 38% to 50%
- Packaging conformance to schedule improved from 92% to 95%
Long-term Impact
- 45% increase in productivity
- 47% OPI improvement
- Over €2 million in structural cost reductions
- 56%–78% reduction in changeover time
- Zero accident rate per 100 FTE
background
Our client aimed to integrate operations at a newly acquired brewery into its global framework while maintaining efficiency and sustainability.
The transformation focused on process alignment, productivity improvements, and embedding a culture of continuous improvement.
the challenge
The integration process presented several key challenges:
- Aligning the new brewery with the parent company’s global operational standards
- Modernising legacy systems and processes
- Performance improvement to enhance safety, efficiency, and productivity
- Managing 530+ SKUs requiring frequent changeovers
- Developing team competencies to support long-term operational excellence
our solution
Henkan was engaged to implement a structured Total Productive Maintenance (TPM) approach, ensuring immediate improvements and long-term sustainability. In partnership with our client, we delivered:
Clear strategic objectives:
Defined KPIs around safety, quality, OPI, productivity, and changeover efficiency in partnership with leadership
TPM training and fundamentals:
Established best practices in 5S, autonomous maintenance (AM), problem-solving, and safety risk reduction, reinforcing sustainable improvement
Optimised changeover and productivity:
Conduced in-depth analyses to streamline operations, reduce downtime, and increase efficiency
Sustainability and scalability:
Implemented continuous improvement structures, regular assessments, and knowledge transfer programmes to embed lasting operational excellence
Implemented continuous improvement structures, regular assessments, and knowledge transfer programmes to embed lasting operational excellence
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