Case Study: Process Improvement in Food Manufacturing with Focus on OEE Optimization

A food manufacturer with demanding product quality standards wanted to significantly increase its production output. The existing processes were characterized by strict quality requirements, complex sequencing in production, and tight constraints in pre-production. At the same time, available floor space was limited and investments in additional equipment were only feasible to a limited extent. Overall Equipment Effectiveness (OEE) varied widely across all lines, with fruit preparation identified as a key bottleneck. Manual and duplicated process steps, along with waiting times, disrupted the production flow and limited the potential for scaling operations.

Miebach supported the client in achieving its ambitious production goals by identifying bottlenecks, optimizing processes, and enabling rapid, practical improvements.

We started with a comprehensive analysis of all relevant processes across planning, production, and intralogistics. Based on this assessment, we developed targeted solution concepts that combined technical and organizational improvements. These included harmonizing capacities between pre-production and main production, designing future-state processes, and applying modern technologies to reduce setup times.

We strengthened the food manufacturer’s planning processes through transparent IT-based tools and implemented a custom dashboard in fruit preparation to improve control. Furthermore, we introduced AI-enabled equipment that helps to identify foreign objects. To support flexible workforce deployment, employees received targeted training.

The developed measures were evaluated based on effort, impact, and strategic alignment, enabling fast implementation of high-priority initiatives.

This project shows that significant performance gains are possible without heavy investments. By combining process transparency, modern technology, and training, we helped our client unlock capacity, eliminate bottlenecks, and build a foundation for continuous improvement.” Miebach Project Lead, Dr. Reiner Friedland, Miebach Consulting GmbH

The implemented improvements significantly increased the client’s production performance without the need for additional equipment. The process landscape was significantly streamlined, resulting in better asset utilization, improved planning transparency, and increased workforce flexibility.
Non-value-adding activities were eliminated, freeing up space and generating sustainable economic value. The solutions delivered not only short-term gains but also established a strong foundation for continuous improvement.