Food & Drink

Good to the last drop – Production Improvement


Good to the last drop – Maxwell House Coffee, a Kraft subsidiary is produced at three sites in the USA.  Each was long established and was faced with reducing market share and low productivity.  Production targets were set at 50% of true capability.

Key issues:

  • Low morale
  • High costs
  • Initiative overload
  • Operators unaware of plant performance
  • Shop floor data was for management
  • Equipment performance and reliability

Project Challenges:

  • To change shop floor attributes
  • Increase morale
  • Increase performance and productivity


MCP facilitated workshops for the shop floor concerned with:

  • Overall Equipment Effectiveness OEE measurement
  • Continuous Improvement
  • Operator Asset Care and TPM

The workshops resulted in project teams being set up to deliver improvements. The teams were empowered to:

  • Identify the problems
  • Develop and implement solutions

Operator Asset Care principles were introduced to the key production lines. This resulted in an increase in equipment reliability and OEE.


The benefits were:

  • Shopfloor teams own their equipment and are accountable for performance
  • True performance information is available
  • Team actions are identified to address losses

The results were:

  • OEE increased by 25% by addressing quick wins
  • OEE levels now regularly hit 85%
  • Increased sales value of $500,000 per day


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