CASE STUDY
Britvic unlocks £5.4M in capacity increase through line balancing optimization
Looking to unlock capacity for your organization?
CHALLENGE
Overcoming production challenges to meet crucial summer volume demands
Britvic PLC, a leading British beverage manufacturer, faces constant pressure to optimize production capacity and meet market demands. Can volume is a critical success factor, and unlocking capacity in this area is crucial.
Delighting their customers with summer beverages and therefore volume is a crucial element in the ongoing success of Britvic’s operations. Britvic reached out to Lineview to help them meet their summer volume demand with existing infrastructure.
SOLUTION
Meeting market demands and gaining an empowered team
Lineview partnered with Britvic to implement a two-week deep dive into line balancing optimization at the Rugby facility. Building from an initial audit using the ‘5 Levels of Control’ line balancing methods, operational experts worked with Britvic’s team to achieve Perfect Flow. Lineview’s proven line balancing template identifies the gap between the current state and perfect conditions. The actions are then defined, and the potential savings are calculated.
By combining expert training, proven methodology, and collaborative implementation, Lineview helped Britvic unlock significant production capacity and empowered Britvic’s team to drive continuous improvement, ultimately gaining a competitive edge in the beverage market.
ABOUT
Britvic is a leading British soft drinks producer headquartered in Hemel Hempstead, England. The company is renowned for its extensive portfolio of popular beverage brands, including Robinson’s, Tango, and R. White’s Lemonade. With a strong presence in the UK, Ireland, France, and Brazil, Britvic also holds exclusive bottling rights for PepsiCo products in select markets.
LineView
Key Benefits:
• Data and AI driven targeted actionable insights
• Seamless integration into existing ERP and MES solutions.
• Automated true causal loss and production monitoring
Methodology Deployment
Lineview’s proven LBO methodology was deployed, focusing on improving control, accumulation, speeds, start-up, and run-out times across the can lines.
Expert Training and Collaborative Implementation
Lineview’s industry experts trained eight Britvic team members in the Line Balancing Optimization (LBO) methodology while closely collaborating with Britvic’s controls engineering team to implement practical line improvements.
“I’m hugely impressed with this intervention. We’ve unlocked significant capacity for our plant and reduced the impact of minor stoppages on our production lines. Most importantly, we’ve equipped our people to be able to go hunt down these opportunities throughout our business.”
Paramjeet Pahdi
Rugby Site Director, Britvic PLC
RESULTS
Unlocked hidden capacity to drive summer volume
Britvic’s partnership with Lineview helped them drive the summer volume successfully by unlocking the hidden potential. The LBO initiative unlocked £5.4M additional capacity, directly impacting Britvic’s bottom line.
Empowered and capable team
The trained Britvic team is now equipped to identify and implement LBO opportunities across the entire organization extending the program to other manufacturing sites of Britvic.
Sustainable improvement
The project instilled an understanding of LBO as an ongoing process, ensuring continuous improvement and maintenance of production efficiency.
£2.5M in further potential identified
Further analysis revealed an additional £2.5M in potential capacity gains through further control optimization.
100%
Empowered team extends LBO organization-wide
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Real-time data transforms decision making
£2.5M
In further potential identified
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