Lean Transformation - Beam Global
Company Profile: Jim Beams Brands, Cincinnati is the largest volume producer of cordials and liqueurs in North America and produces dozens of varieties of cordials, including those sold under the DeKuyper® name. They also package other products such as bourbon, gin, vodka, rum, and Canadian whiskey.
Project: As a company rooted in tradition, Jim Beam Brands, Cincinnati has been processing spirits in nearly the same manner for the past 40 years. Despite its static operations, the company was extremely progressive concerning quality. There was a constant increase in the popularity and demand of its products, and in 2005 it further expanded its range through the acquisition of several leading spirit and wine brands. Wanting to stay ahead of the curve in terms of efficiency, quality, and profitability, Jim Beam Brands, Cincinnati, began building a new corporate culture from the ground up.
Over the course of several years, the company has partnered with TechSolve on multiple projects in an effort to evolve their processes as well as their culture. The team is working together through the entire plant, one area at a time, in pursuit of the continuous
improvement of the plant.
The Lean transformation began by building momentum in the production area. TechSolve worked with all levels of Jim Beam Brands, Cincinnati staff to uncover non-value-added (wasteful) aspects of the production process. After identifying problem areas, solutions were designed and implemented according to their potential for positive impact. The team also reorganized the production area, which decreased inventory, increased space, and enhanced worker safety.
Results: By eliminating wasteful items, time, and activities from the production area, Jim Beam Brands, Cincinnati experienced a reduction in both changeover and setup time. Employees were able to produce the same volume in fewer hours, which resulted in:
- A lead time reduction of approximately three hours
- $4.5 million in potential cost savings
- The creation of four continuous improvement positions
“The value of work and quantifiable improvements we’ve made during our lean Initiative with TechSolve has exceeded my expectations. Absolutely one of the best returns on investment we’ve made.”
Paul Houston, Plant Manager, Jim Beam Brands, Cincinnati
