Results Delivered in the Field

The Challenge

A high-volume dairy packing site was consistently achieving OEE of around 58% on its primary filling line — well below the designed capacity. Management had attributed the losses to ageing equipment, but no systematic analysis had been carried out.

Our Approach

HES Consulting conducted a structured OEE study over two production weeks, mapping all downtime events, speed losses, and quality rejects. The analysis identified a filler timing drift as the primary throughput constraint, compounded by a changeover process that had grown to nearly 90 minutes through accumulated informal practice.

The Outcome

Following targeted adjustments to the filler timing parameters and a redesigned changeover procedure with operator coaching, OEE improved from 58% to 81% within six weeks. Changeover time was reduced to 47 minutes.

The Challenge

A juice packing facility operating across three shifts had no structured maintenance programme in place. Reactive breakdowns were averaging four per week, with an average resolution time of three hours each — consuming significant engineering resource and disrupting production schedules.

Our Approach

HES Consulting developed a bespoke Total Productive Maintenance System tailored to the site's specific line configurations and production windows. This included condition monitoring protocols, a wear-part replacement schedule, and documentation aligned to the site's compliance requirements. The maintenance team was trained on the new procedures over a two-week handover period.

The Outcome

Within three months of implementation, reactive breakdowns had reduced by 74%. Average resolution time for the remaining incidents fell to under 45 minutes as root causes were better understood and spare parts were held appropriately.

The Challenge

A soft drinks manufacturer was commissioning a new high-speed PET filling line. The equipment supplier's project timeline was aggressive, and the internal engineering team lacked experience with this class of filler. Previous installations at the site had overrun significantly, and the business needed independent oversight to protect the go-live date.

Our Approach

HES Consulting provided independent project management from FAT through to production sign-off. This included vendor milestone tracking, on-site presence during installation and commissioning, SAT execution, and a structured trials programme to validate performance against the agreed specification. Operator and maintenance training was delivered in parallel with the commissioning phase.

The Outcome

The line achieved production sign-off on schedule — the first on-time installation the site had completed in four years. Performance during the first month of production exceeded the contracted throughput specification by 6%.