Following the integration of EFES facilities in Russia the business rationalised its manufacturing plants.
This re-alignment in breweries drove capacity constraints into the remaining manufacturing locations as the sites were being asked to produce more volume and accommodate a bigger range of SKUS.
Understanding the potential for unlocking capacity
EFES wanted to understand the potential for unlocking capacity within the remaining infrastructure and asked BiS Henderson Consulting to review operations at a range of breweries. This project identified a range of capacity enhancing initiatives that enabled the customer to hold more inventory in the same amount of space thereby saving on external temporary storage. The review process involved the development of a comprehensive and precise understanding of existing building layouts and capacities. We validated, measured and assessed building dimensions and then evaluated the aisle width requirement to ensure safe truck operations. We also assessed the impact on capacity of the master production and master outbound despatch schedules and evaluated the impact of moving product between multiple warehouses within the factories.
To enable the identification of the best locations for the storage of certain products types we also reviewed a range of operational process and management changes that could enable greater density of product storage by, for example, taking steps to enable higher product stacking in blocked stack locations and creating greater stability of product through use of better handling media and product security measures.
“Bis Henderson Consultancy and their involvement in our project has enabled a step change in thinking”
Adam Gunn, Technical Director for EFES
The capacity generating actions were site specific as were the results:
Kaluga Improvement in capacity
Kaluga Improvement in capacity: 26%
UFA Improvement in capacity
UFA Improvement in capacity: 31%
Kazan Improvement in capacity
Kazan Improvement in capacity: 20%
Annual external storage costs in Novosibirsk
Annual external storage costs in Novosibirsk: 100%