Worldwide leader in convenient snack Foods & Beverages
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Quality issues in new products emerged as a significant challenge, primarily due to a lack of statistical discipline within the R&D organization and process inefficiencies stemming from multiple quality standards.
Furthermore, the new product introduction (NPI) process was hampering the timely and efficient introduction of new products. Compounding these issues was a sub-optimal lab structure, which failed to support R&D projects adequately. This combination of factors led to delays, increased costs, and challenges in maintaining high-quality standards across new product lines, highlighting the organization’s critical need for process and structural improvements.
An extensive worldwide assessment of the beverage quality assurance organizations and their core practices was conducted, leading to the customization of Greenbelt/Blackbelt training to improve the New Product Introduction (NPI) process. This initiative mapped the current and future state of the core ingredient release process as it relates to volume production. This comprehensive mapping covered formula development, manufacturing, equipment design, packaging, and the implementation of measurement and traceability systems.
To further enhance efficiency, a pull system was implemented in lab workflows. This system significantly eliminated physical and process wastes, streamlining operations and bolstering overall productivity in developing and introducing new products.
At a Glance
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Results