Case Study
Fast Moving Consumer Goods
c. £1.3m
Annualised Savings
Service line
Business Excellence
12 month
Syngroup Office
Cranfield / UK
UK, 5 sites
Fast Moving Consumer Goods (FMCG)
Our client is one of the largest producers of packaging in glass, paper, metals and plastic.

The company operates in 12 countries across Northern and Southern Hemispheres, employing c. 6,500 people.
To deliver improved operating costs, our client sought our expert support in the implementation of efficiency improvements, specifically targeting bottom-line savings.
The project was based in the United Kingdom, predominantly at our client’s largest manufacturing site.

  • Identify and deliver a reduction in operating costs.
  • Improve efficiency by 15 percentage points in Overall Equipment Effectiveness (OEE).
  • Target and track benefits to the P&L.

Provide support across all management levels through the transition period;

  • From: Lack of a structured approach to continuous improvement, high staff turnover and low motivation of workforce
  • To: An engaged workforce with Plan, Do, Check, Act (PDCA) as its core operating principle
Focus area
Supply Chain
Human Resources / Training
Change Management
Our Approach
  • The engagement commenced with a short scoping exercise across several UK sites, after which the UK’s largest site was chosen to carry out a further “deep-dive”. This was done across all operational departments i.e. Production, Maintenance, Planning, Logistics etc.
  • Our findings showed there were significant opportunities for improvement, which led to a 10 month design and implementation project. The initial objective was to stabilise production through the introduction of standard operating procedures and working practices. This was followed by a period of focussed process improvement and change management across all operations departments.
  • We worked bottom-up and top-down, involving the workforce in the analysis and implementation phases to incorporate their knowledge and ensure there would be ownership of solutions.
Annualised savings of £1.3m through a reduction in direct, indirect staff and operating costs
Cost savings were made possible through improved equipment efficiency, enabling output and quality to be maintained using fewer personnel
Realised benefits are being under-pinned by a robust continuous improvement process, supported strongly by local management
  • Overall Equipment Effectiveness (OEE)
  • Change Management
  • Project Management
  • Planning & Control
  • Total Productive Maintenance (TPM)
  • Digitalisation