validus management consultancy UK

Food & Drinks Case Study

UK gin manufacturer

Improved maintenance process and procedures...
Reduced downtime and increased output


The UK's leading manufacturer and supplier of gin


  • Following a catastrophic fire, the company had re-invested in key plant and machinery
  • Key machines were still experiencing high levels of unplanned downtime and loss of production
  • The skills levels on site were mixed and not aligned to the new plant and equipment
  • Need to strengthen engineering and maintenance systems as part of an initial strategy to improve overall site performance


  • Initial project ‘scoping’ exercise carried out to understand the technical, process and ‘cultural’ issues on site
  • Established internal team to work jointly to construct improved engineering and maintenance processes and procedures
  • Detailed analysis of current maintenance procedures and practices, focusing on Autonomous Maintenance (AM) and Planned Maintenance (PM)
  • Detailed analysis and re-categorisation of downtime to establish root cause of problems
  • Developed and implemented improved AM and PM maintenance procedures with clear roles and responsibilities between operating and maintenance staff for key items of plant
  • Provided the template to enable improved procedures to be rolled out across the rest of the site
  • Implemented strong ‘5S’ visual management techniques to emphasise key learning points and make maintenance performance more visible
  • Developed improved KPI collation, reviews and action planning


  • Strong levels of buy-in to proposed systems
  • Following implementation on pilot machines, the procedures were subsequently rolled out across the site by internal team members and other staff with high levels of ownership
  • Significant improvements to line downtime. This translated into additional capacity / opportunity to produce around 250,000 cases per annum and gain associated additional margin