Starch manufacturer wanted to deploy formal process improvement to support growth and competitiveness

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The business

We worked with one of the largest manufacturers of potato starch used in the food, paper, textiles, adhesives, feed and building industries. Key stakeholders included over 3,500 farmers who are co-operative members of the company which had an annual turnover in excess of £500 million and employed over 1,400 people

Their needs

The business faced pressures due to varying crop yields and cheaper alternative products. They wanted to deploy a robust process performance programme that would support growth and competitiveness.

How we helped

We assisted our client with their Lean Six Sigma deployment across several large sites during a period of company reorganisation whilst maintaining productivity. 
We delivered multiple Green Belt, Black Belt and Champion Lean Six Sigma workshops, supported with on-site coaching and mentoring, deployment advice and project selection workshops. Further training and guidance was provided to develop their internal Master Black Belts to enable an effective transition to local ownership.

Projects included

• Reduce the volume of potato rest starch
• Reduce unplanned downtime on extruder
• Reduce the volume of water requiring evaporation
• Increase starch throughput
• Reduce microbiology test time
• Reduce number of dryer sieve gauze breakdowns
• Reduce non-dust related rejects
• Optimise capacity in drum drying

Benefits achieved

During our involvement 20 projects were completed delivering a 17 fold return on investment. Several years later, the staff we developed continue to teach and mentor colleagues in waste and defect reduction projects within their manufacturing processes.


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