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Observe, Plan, Engage and Nurture. Based on more than 100 years of combined experience of implementing Operational Excellence and manufacturing improvement in fast-moving consumer goods (FMCG) factories. The OPEN continuous improvement system is the key to unlocking productivity improvement for the type of factories that service the FMCG sector.
Achieving Operational Excellence (OpEx) and World Class Manufacturing (WCM) traditionally involves using consulting firms to implement continuous improvement systems, Lean programmes or Six sigma approaches. That works for large factories, but getting to effective on an OpEx framework shouldn’t need to take external support. There is now another way to access the valuable information for World Class Manufacturing practices, Kaizen systems, and achieve operational excellence in manufacturing and operations management.
An off-the-shelf continuous improvement (CI) system is a new idea. You will need to take care to choose what is right for you. However, herein you will find videos, animations, and resources to teach you the hidden mysteries of sustaining continuous improvement and how to make rapid productivity gains.
The framework is structured around OPEN – a type of manufacturing improvement audit, or Lean audit. It allows you to put a measure on operational excellence, whilst defining a world class manufacturing methodology to implement. Whether it has been about implementing 5S in manufacturing or tracking the progress of meetings, CI audits have long been used as an essential element in sustaining manufacturing improvement, and in building operational excellence.
FMCG refers to the manufacture of Fast Moving Consumer Goods – that includes Food, Beverage, household goods such as bleach or cleaning products, over the counter pharmaceuticals, some textiles – essentially if you buy it in a supermarket or large high street store, it’s definitely a consumer good, and probably fast moving (not literally as whizzing about on legs – fast moving as in selling lots of them😊).
People often don’t think about it – but UK FMCG manufacturing is the largest single manufacturing sector, larger than automotive and aerospace combined – and if you think about your weekly shopping bill compared to what you spend going on flights and on your car, it probably shouldn’t be so surprising.
It is a wide sector – sometimes unfairly called a “Sector of Sectors” - but there are strong commonalities. It doesn’t really matter if your putting bleach or cod liver oil in a bottle, then into a carton, outer, and onto a pallet – the problems are surprisingly similar.
FMCG is characterised by lower requirements for asset utilisation than other manufacturing sectors such as chemical or automotive – essentially the machines are cheaper to buy, but take more people to run. It also typically has a range of skilled and unskilled workers, and therefore the need for strong people engagement is essential to the long term success of the business.