Client Background

A small but growing vegetable-based health juice company produces fresh juices daily for local retailers and direct-to-consumer deliveries. As demand increased, the owner noticed inefficiencies in production scheduling, ingredient management, and delivery planning, leading to waste, delays, and occasional stock shortages.

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Problem Statement

1. Production schedules were inconsistent, leading to overproduction of some juices and shortages of others.

2. Ingredient tracking relied on manual logs, resulting in errors and spoilage.

3. Delivery routes were planned ad-hoc, increasing transport time and costs.

4. There was no centralised documentation for recipes, production procedures, or delivery processes, making staff onboarding and compliance difficult.

 

Objectives

1. Audit the current production and delivery processes to identify inefficiencies.

2. Standardise documentation for recipes, production procedures, and delivery protocols.

3. Reduce waste and optimise resource usage.

4. Improve delivery planning for faster and more reliable customer service.

 

Approach & Methodology

Our team applied a Comprehensive Process and Documentation audit:

 

1. Discovery & Observation

• Shadowed production staff and delivery personnel to understand current workflows.

• Collected existing documentation, logs, and spreadsheets.

• Conducted interviews with staff to identify pain points and bottlenecks.

1. Process Mapping & Gap Analysis

• Created detailed workflow maps for production, inventory management, and deliveries.

• Highlighted inefficiencies, duplications, and manual errors.

• Identified critical control points for quality and compliance.

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2. Documentation Standardisation

• Developed standardized SOPs for production, ingredient handling, and delivery routing.

• Created templates for daily production schedules, stock tracking, and delivery logs.

• Recommended central storage for all documentation with version control.

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3. Recommendations & Action Plan

• Proposed workflow optimizations, including batch scheduling and route planning.

• Suggested training for staff on updated procedures and documentation.

 

Solution

The final deliverables included:

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1. ​Standardized SOPs for production and delivery

2. Templates for ingredient tracking, production schedules, and delivery logs

3. Process maps highlighting bottlenecks and improvement opportunities

4. Recommendations for workflow optimisation and waste reduction

5. Training plan for staff on new procedures

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Results & Impact

1. Reduced ingredient waste by 30% through better inventory and production planning.

2. Delivery efficiency improved by 25%, reducing delays and transport costs.

3. Staff were able to follow clear procedures, reducing errors and confusion.

4. Onboarding new staff became faster and more structured.