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LeanEdge, LLC - CASE STUDY
Shrink Reduction (Project Emerald) - Dairy Processing

 Company - Dairy Processing facility in Colorado.

Situation - Operations audit identified unacceptable shrink losses during milk processing with an identified potential savings of over $500,000 per year.

Plan - Establish process improvement teams in three areas (Processing, Fillers Area, and Cottage Cheese) with LeanEdge experts assuming coaching role for team leadership while coordinating the project portfolio over a nine month period.

Selected Projects Undertaken
Processing
  1. Line installation and commissioning of flow meters, air eliminator and in-line sampler unit

  2. Recovery of cold burst rinse at truck receiving

  3. Recovery of cream rinses from Raw Tanks

  4. Eliminate Fat Giveaway for 2% product

  5. Establish and implement fat sequence control and correct product scheduling

  6. Establish and implement minimum batch sizes at the HTST (High Temperature Short Time)

  7. Revise HTST cleaning schedule

  8. Develop a coordinated production planning program from warehouse to shipping

  9. Establish a framework for complete measurement and control of milk volume, fats and solids

Fillers
  1. Testing, quantification and recovery of product discharge waste loads at fillers

  2. Minimize product giveaway at Federal and paper fillers

  3. Review line CIP (Cleaning In Place) programs

  4. Reduce jug-to-jug variation

Cottage Cheese
  1. Implement yield measurement and control program

  2. Implement SPC program

Results - Significant overall shrink reduction across many areas, including a 123% realization of targeted filler giveaway reduction netting $55,000 in annualized savings.

For more information call (912) 233-9945, write to info@leanedge.net or visit our website at www.leanedge.net.




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