Sometimes the biggest breakthroughs come from solving the "unsolvable" problems that everyone else has given up on – this food manufacturer discovered how the right consultant turned a lingering operational challenge into a major competitive advantage.
A food manufacturer launched a new production line that met requirements, but could not efficiently switch between certain SKUs. Each changeover required a shutdown, Clean-in-Place procedures, and piping changes that broke sanitary boundaries, which created extended downtime to meet FDA aseptic food handling requirements.
Prior solutions required expensive piping modifications and revalidation. Management was unwilling to restart validation or delay full production launch for what seemed like a secondary efficiency issue.
The breakthrough was that the limitation was software, not hardware.
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