Faced with a critical operational challenge, the Client, a pioneer in the craft brewing sector, was constrained by an outdated packaging system that limited overall line efficiency to just 40%. This bottleneck threatened production goals and growth ambitions, requiring a solution that would double efficiency and streamline packaging operations for long-term scalability.
First Key approached the challenge with a holistic, data-driven strategy. We designed a new packaging line to address efficiency gains, orchestrating project execution within a tight three-week window while ensuring uninterrupted can line operations during construction and startup. Leveraging advanced engineering and project management tools, including AutoCAD, MS Project, and Excel, we delivered comprehensive Standard Operating Procedures (SOPs) and provided targeted training for operators and maintenance technicians. Our solutions prioritized equipment compatibility, maintenance accessibility, and seamless system integration, aligning with the Client’s current and future production needs.
The results were transformative. The project was delivered under budget and ahead of schedule, with the new line achieving a total line efficiency of 68% OEE—an impressive 70% improvement over the previous benchmark. The individual line packer reached over 90% OEE. These quantifiable gains empowered the Client to scale packaging operations, unlock new business opportunities, and position themselves for sustained growth in a competitive market. In partnering with First Key, the client not only solved the immediate challenge but also created a foundation for future success.
