The Client faced mounting operational challenges within their brewing department that constrained performance and limited growth. Legacy SOPs had gone untouched for more than seven years, resulting in inconsistent production scheduling, quality deviations, and uneven technological adoption across teams. With low staff engagement, training gaps, and a lack of standardized KPIs or digital reporting, the department struggled to scale effectively, respond to contract opportunities, or maintain consistent product quality.
To address these issues, First Key deployed an Interim Brewmaster supported by a cross functional team to lead a comprehensive Brewing Reset. The team introduced a new production scheduling process and implemented a Cold Store Process that improved inventory control. They developed KPIs with supporting dashboards and control charts to bring visibility to management and the board. A full SOP gap analysis informed the update and creation of critical documentation, while clearly defined SLAs improved coordination with packaging operations. First Key also designed and delivered a robust training matrix, reference binder, onboarding plans, and targeted technological upskilling. To strengthen accountability and workflow clarity, the team created a RACI chart, enhanced preventative maintenance schedules, and implemented a digital work request system. Additional support included contract development, sugar brew trials, and technical sales materials that accelerated the Client’s commercial initiatives.
As a result, production scheduling improvements reduced over aged beer inventory by 23 days, strengthening FIFO discipline and lowering holding costs. KPI dashboards enabled data driven decisions across all management levels, while updated SOPs and training elevated staff proficiency and engagement. Improved maintenance and process controls enhanced product consistency and equipment reliability. New contract products were successfully launched, including a reformulated sugar brew that generated positive market feedback. The engagement not only stabilized operations but positioned the Client for scalable growth, higher margin innovation, and future commercial expansion.
