Throughput Improvement with Lean Deployment at Callan Bacon

Client Name:

Callan Bacon


About Callan Bacon

Callan Bacon is a family run pork and bacon processing company based in Callan, Co. Kilkenny. The company has been in business since 1924 and moved to a purpose built 54,000 sq.. premises in 1990. Annual turnover is over €40M and the company has the capacity to process 45,000 tons of product per annum.  Callan Bacon employ 140 people.

Key Programme Objectives

  • Increase throughput per person in the plant.
  • Direct engagement with employees to support the setting up of a continuous improvement culture.
  • Establish teamwork on processing lines.
  • Train and implement as many Lean tools as are needed to improve the performance of the operation.

Putting Lean into Practice

  • Leadership training plus Management and Supervisory Lean training.
  • Standardised method for developing and reviewing performance against KPIs across the plant
  • Conducted daily PIT meetings where issues were openly discussed and resolved.
  • Setout a long term strategic plan for the company with clear objectives.
  • Setup and mentored continuous improvement teams focused on exceeding milestones set-out in the strategic plan.
  • Improvement in master planning process to improve availability of products.
  • Developed Standard Work method to understand and improve changeovers on the processing lines.

The Results

  • All Management, Supervisors and lead hands taken through and deployed Lean tools to improve the operation
  • Increased the throughput of the plant by 33%
  • A strong continuous improvement (CI) culture has been developed through teamwork  on the site.
  • Significant technical breakthroughs and cost savings have been achieved through CI teamwork projects.
  • A robust capacity planning module has been developed for the site.
  • Capability to deploy a wide variety of Lean tools for problem solving into the future.

Framework tools applied

  • Process Mapping
  • Strategic Deployment
  • Standardisation of KPIs
  • Lean Sigma Green Belt Training
  • Problem Solving
  • PIT Meetings
  • Standard Work
  • Process Planning Improvement
  • A3 Methodology
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