FMCG Manufacturing Efficiency: How Prime Design Improves OEE and Reduces Production Costs
FMCG Manufacturing Efficiency: How Prime Design Improves OEE and Reduces Production Costs
Operations Optimisation in FMCG: Improving OEE, Reducing Costs, and Boosting Reliability
Design. Validate. Visualise.
In the competitive world of FMCG manufacturing, every second counts. A small inefficiency in one step of the process can ripple across your entire line, reducing throughput, increasing costs and affecting delivery performance.
At Prime Design, we specialise in Operations Optimisation; helping manufacturers identify hidden inefficiencies, improve Overall Equipment Effectiveness (OEE), and create smoother and more reliable production processes.
Are You Getting the Best from Your Production Line?
Even well-established production systems can experience performance drift or unseen bottlenecks. Whether your line is underperforming or a new installation hasn’t met expectations, Prime Design provides tailored solutions to diagnose and resolve operational challenges.
Common issues we solve include:
🔹 “Our production efficiency has dropped, but nothing has changed.”
We offer Manufacturing Operations Surveys to uncover the root cause and prioritise key improvement areas.
🔹 “The new line never reached its expected output.”
We evaluate fundamental design or acceptance test issues to bring the line up to spec.
🔹 “Our teams no longer believe we can reach our targets.”
We support the implementation of Continuous Improvement (CI) frameworks to rebuild performance and confidence.
🔹 “We’re considering buying new equipment, but we’re not sure it’s the solution.”
Our simulation modelling helps you make data-driven decisions and justify CAPEX investment before committing.
What Is OEE and Why It Matters
Overall Equipment Effectiveness (OEE) is a crucial metric in FMCG operations. It combines three key components:
- Availability: Percentage of planned production time your line is running.
- Performance: Speed at which equipment runs compared to its ideal rate.
- Quality: Proportion of good units produced.
A perfect 100% OEE means your equipment is producing only good products, as fast as possible, with no downtime.
Tracking OEE helps you identify where productivity is being lost, benchmark progress, and measure the impact of improvements, making it the single most important KPI for manufacturing efficiency.
How to Improve OEE on Your Production Line
Improving OEE requires a strategic, data-led approach. At Prime Design, we help you:
- Define objectives – Establish whether you’re benchmarking, troubleshooting, or targeting profit growth.
- Select the right metrics – Consider OEE, OOE (Overall Operations Effectiveness) or TEEP (Total Effective Equipment Performance).
- Automate data collection – Use IIoT sensors for real-time visibility and performance tracking.
- Apply Lean methodologies – Follow the DMAIC cycle (Define, Measure, Analyse, Improve, Control).
- Sustain improvements – Build a Continuous Improvement culture that delivers long-term gains.
Reducing Operating Costs in FMCG Manufacturing
Cost optimisation is a top priority in any production environment. Our experts work with your teams to:
1. Assess Production Line Equipment
Ensure machinery integration, calibration and speed alignment are optimised across all process steps.
2. Minimise Material Waste
Refine packaging specs, implement precise filling systems and reduce product loss.
3. Improve Energy Efficiency
Introduce energy-saving systems, monitor idle machinery and deploy smart sensors to reduce consumption.
4. Strengthen Preventive Maintenance
Predict issues before they occur using data analytics, reducing downtime and extending asset lifespan.
5. Enhance Labour Efficiency
Invest in operator training, shift optimisation, and effective team management.
6. Optimise the Supply Chain
Negotiate better supplier terms, manage inventory levels, and monitor logistics costs.
Engaging and Empowering Your Workforce
Your people are the key to sustainable operational success. We help you:
- Listen and act on employee feedback.
- Invest in professional development and cross-training.
- Recognise and reward achievement to boost morale.
- Promote collaboration and teamwork.
- Maintain fair pay and benefits to retain talent.
Engaged employees drive efficiency, innovation and quality; the cornerstones of a high-performing FMCG operation.
Prime Design’s Operations Optimisation Services
At Prime Design, we combine engineering expertise with advanced modelling tools to help FMCG manufacturers maximise output and reliability.
🔹 Simulation Modelling
We use advanced simulation tools to test process parameters — such as speeds, conveyor lengths, accumulation, and staffing — in a virtual environment before implementation. This ensures you get the right solution with reduced cost, risk, and downtime.
🔹 Manufacturing Operations Survey
Our focused site surveys deliver a data-backed report highlighting strengths, inefficiencies, and opportunities for improvement.
🔹 Continuous Improvement (CI) Frameworks
We implement practical CI systems that empower your teams to solve problems, reduce waste, and continuously improve performance.
Why Partner with Prime Design?
With decades of combined FMCG operations experience, our team brings unmatched technical expertise to every project. We partner with our clients to drive excellence in Quality, Cost and Delivery (QCD), ensuring sustainable and measurable results.
📍 Address:
Centurion House, London Road,
Staines-Upon-Thames, TW18 4AX
📞 Phone: 01784 668188
📧 Email: info@primedesignprojects.com
🌐 Website: www.primedesignprojects.com
Prime Design – Design. Validate. Visualise.
Delivering smarter, leaner, and more efficient FMCG operations.