CDC Factory

Calypso Soft Drinks Ltd.

CDC Factory helps Calypso Soft Drinks slash raw material costs by one percent

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Customer Snapshot

Founded as a dairy company more than 120 years ago, Calypso Soft Drinks Limited now focuses on producing single-serve organic drinks made with natural mineral water from Calypso's own source. The company produces more than 500 million soft and frozen units per year, which it sells to customers ranging from supermarkets to retailers, airlines, schools, hospitals and prisons.

Challenges

  • Company was looking for ways to reduce costs
  • Efforts to reduce waste with an activity-based costing (ABC) project were hindered by a lack of visibility at the manufacturing level
  • The company had a lot of data, but it was all driven by spreadsheets—it was completely manual, time-consuming and at least 24 hours behind the event
  • Additional problems were accuracy and consistency of data, resulting in production continually being about 70 minutes, or five percent, short on allocated downtime

Results

  • 30% reduction in stock
  • 3% – 5% productivity improvements per line
  • 80%+ OEE consistently running on all lines
  • 1% reduction in raw material costs
  • Improved shift changeover time by providing shift leaders with online end-of-shift reports to evaluate productivity and brief the next shift in seconds
  • Increased productivity by providing operators with real measures against which they can improve
  • Reduced minor line stoppages while eliminating product waste