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Results

  • Implementation plan including ten year planning & investments
  • No additional bottling plant required to achieve growth figures (investments over € 20 million)
  • Focus on improving and extending existing site within the organisation
  • Resulting in significant operational logistics costs saving (exceeding 15%) and performance increase (factory output will be increased with factor 2,5)

Our solution

UC Group has performed a Strategic Road Map to increase on-site safety as well as significant capacity growth in the following ten years, including high-level timelines and investment budgets. This first phase of the project was performed in an intensive 12-week program with bi-weekly workshops with customer representatives and UC Group consultants.

After delivery of the Strategic Road Map and the future design of end-ofline production and warehouse layout, the roll-out of the plan has been done by a joint project team of Irish Distillers and UC Group, in which UC Group has (among others) performed roles like:

  • IT project management for MES implementation
  • Data analysis of volume growth figures (on a yearly base) to validate plans with updated reality
  • Support on RFQ for mechanisation supplier selection
  • Validation of selected solution for implementation against Strategic Road Map philosophy
  • Analysis & advice on safety and flows of yard truck movements
  • Storage requirement analysis for further growth based on volume growth figures

Customer challenge

To what extent can we maximise our plant and warehouse output, with safety as the top priority? And what high-level programmes are needed to achieve this?

The customer was a WMS implementation to separate its ERP and warehouse activities but had no insight into the long-term impact of its considerable annual growth on its warehouse and production processes. It had even been considering the option of building an additional bottling plant. As part of the process of setting out the road map for the next ten years, UC Group was asked to advise on production and logistics processes, safety and business cases. This involved:

  • Strategic consultancy
  • Data analysis – change management and team alignment
  • IT project/implementation management – analysing and advising on on-site safety and transport flows
  • Consultancy on planning and forecasting for production and warehouse processes
  • Setting up a line change-over matrix and process capacity model for each activity

Throughout the process, the IDL team was involved and challenged in the next steps so as to make sure the local team fully supported the chosen solution. This involved a series of workshops (off-site), shop floor visits and in-depth data analysis.

During a very critical time the team of UC Group delivered us a clear strategic vision for the future by combining engineering and pragmatic implementation skills in planning and IT project management. Thank you for your help and looking forward your continue assistance.

Tommy Keane, Production Director, Irish Distillers