New Belgium Brewing Co.

Goals

• To increase the company’s ability to fully take advantage of manufacturing capabilities
• Achieve Overall Equipment Effectiveness (OEE) to produce a quality product; manage production efficiency; and ensure production line availability through scheduled downtimes, package changes, and scheduled maintenance activities
• To operate the brewery at full production capacity and double case production

Challenges

• The brewery lacked real-time information on unscheduled downtimes at various equipment
  areas which caused production slowdowns
• Production staff were continually reacting to unscheduled downtime at equipment areas
• Management needed to address gaps in methods and processes to drive improvements
• The bottling operation lacked the ability to predict capabilities to effectively commit brewery staff to specific production goals

Results

• OEE increased from 45% to 65% in just over 2 years
• Decreased downtime by more than 50%
• Efficiency of scheduled run time increased by 25% - 30%
• Achieved record production weeks producing 190,000 to 200,000 cases consistently,
  successfully meeting customer demands
• Extended packaging area capacity to about 1.3 million barrels each year
• The brewery was able to delay capital investments, enabling it to
  maintain lower operating costs

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