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Breyers Tackles Manufacturing Operations Management
Yogurt company increases production efficiency more than 15 percent, improves customer order fill rates with CDC Factory MOM system
Atlanta — February 20, 2008 — Breyers Yogurt has increased production efficiency by more than 15 percent, improved visibility and accountability throughout its plant floor operations, and improved its customer order fill rates after implementing CDC Software's CDC Factory solution, the software company has announced.
Breyers chose CDC Factory over three other systems because the CDC solution was the only out-of-the-box packaged solution that could be rapidly deployed and because the company felt that the software offered the key functionality it needed for current and future requirements as a food processor.
With CDC Factory, Breyers has measured a reduction in downtime due to production line changeovers of approximately 30 percent. This has been accomplished by identifying specific root causes of inefficiency. CDC said that its Factory solution is the first packaged manufacturing operations management (MOM) system that transforms manufacturing performance by empowering the factory floor to take immediate action.
Extra Day's Worth of Product
In terms of productivity, the improved changeover time has allowed Breyers to achieve significantly higher production throughput. The company can now produce in five days what previously required six days, resulting in a choice of either an extra day's worth of product each week or a substantial reduction in overtime costs. Other improvements achieved by Breyers include improved portion control and accountability, improved customer order fill rates, and additional accurate root-cause analysis.
"We are extremely satisfied with the implementation and immediate results using CDC Factory," said Matt Davis, business unit manager at Breyers. "Rapidly rising costs tied to energy, fuel, transportation and materials are driving food processors throughout the industry to make adjustments to preserve their profit margins."
Davis said that with the efficiency gains Breyers has already achieved with CDC Factory, the company has taken significant steps toward improving its operating margins, and Breyers expects to realize further gains going forward. "Achieving these goals will give us a significant competitive advantage, especially in the current global economy," he said.
Breyers chose CDC Factory over three other systems because the CDC solution was the only out-of-the-box packaged solution that could be rapidly deployed and because the company felt that the software offered the key functionality it needed for current and future requirements as a food processor.
With CDC Factory, Breyers has measured a reduction in downtime due to production line changeovers of approximately 30 percent. This has been accomplished by identifying specific root causes of inefficiency. CDC said that its Factory solution is the first packaged manufacturing operations management (MOM) system that transforms manufacturing performance by empowering the factory floor to take immediate action.
Extra Day's Worth of Product
In terms of productivity, the improved changeover time has allowed Breyers to achieve significantly higher production throughput. The company can now produce in five days what previously required six days, resulting in a choice of either an extra day's worth of product each week or a substantial reduction in overtime costs. Other improvements achieved by Breyers include improved portion control and accountability, improved customer order fill rates, and additional accurate root-cause analysis.
"We are extremely satisfied with the implementation and immediate results using CDC Factory," said Matt Davis, business unit manager at Breyers. "Rapidly rising costs tied to energy, fuel, transportation and materials are driving food processors throughout the industry to make adjustments to preserve their profit margins."
Davis said that with the efficiency gains Breyers has already achieved with CDC Factory, the company has taken significant steps toward improving its operating margins, and Breyers expects to realize further gains going forward. "Achieving these goals will give us a significant competitive advantage, especially in the current global economy," he said.
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