Food manufacturing
A bespoke Manufacturing Excellence Academy combined immersive learning, live workplace projects and coaching, helping a global food manufacturer build internal capability and deliver measurable financial benefits.
Reported results from earlier Academy cohorts. These figures relate to delegates’ first improvement projects and exclude subsequent diagnostic work.
The challenge
A large global food manufacturer wanted a consistent Manufacturing Excellence approach across its international network. Lean principles, daily management routines and problem-solving methods varied between sites and departments, limiting consistency and impact.
Gaps in performance visibility and KPI ownership made it harder to identify constraints and understand losses. Our client needed practical internal capability, supported by more consistent leadership routines and asset-care practices.
Our approach
Project7 designed a bespoke Academy around our client’s manufacturing environment. A training-needs assessment and tailored instructional design shaped an immersive ten-day programme, delivered by two experienced facilitators.
The curriculum combined Manufacturing Excellence principles, workplace organisation, visual performance management, policy deployment, standard operations, asset care, structured problem solving, Value Stream Mapping and the role of the leader.
Learning through real manufacturing work
Practical simulations, Go Look See activity and examination of real processes reinforced classroom learning. Delegates explored how the methods applied in their own operating environment.
Applying the learning to a live project
Each delegate returned to the workplace with an improvement project. Structured coaching days, A3 reporting and milestone reviews supported application. Operational and financial measures made progress visible, culminating in presentations to senior leaders.
Building the capability to keep improving
Selected participants developed the skills to support later cohorts and coach colleagues. Process confirmation, benefit tracking and phase reviews helped sustain the approach. Participant feedback informed improvements between cohorts.
Results and lasting capability
- Earlier cohorts generated average financial benefits exceeding £74,000 per delegate from their first workplace improvement project.
- Reported return on investment exceeded 20:1 in earlier Academy cohorts.
- First projects typically reached completion within approximately ten weeks of attending the Academy. These figures describe the initial application of learning, rather than a lifetime total.
- Delivery expanded through multiple cohorts across the UK, Ireland and Asia Pacific, involving participants and projects from the UK, Ireland, Australia and New Zealand.
- The Academy established a common Manufacturing Excellence language and a more consistent approach to daily management, problem solving and improvement.
Delegates developed the capability to lead further projects and coach others, helping our client strengthen improvement capability across its manufacturing network.
What delegates say
“Excellent learning experience, made me broaden my perspective of problem solving and how I can apply my knowledge to my department.”
“It was an excellent hands on course that encouraged practical learning and collaboration between all areas of the business.”