Case Study – CPG Manufacturer Leverages LEAN for Savings
Driving Productivity with LEAN Across Making, Packing, and Distribution
Over $250K in savings and measurable productivity gains through hands-on continuous improvement
❝SPARQ360 has made a major contribution to Accupac by helping us implement lean tools to reduce cycle time and improve productivity. They work with us in a thoughtful and professional manner and bring the team along to create ownership and commitment.❞
Raj Lall
Accupac
A consumer packaged goods manufacturer struggled with inefficiencies across its production and distribution operations. Lacking internal LEAN expertise, the company faced challenges in scheduling, maintenance, and execution—resulting in lost productivity and avoidable costs. SPARQ360 partnered with the team to reapply proven LEAN tools and processes, driving significant improvements over 18 months.
The Challenge
Despite strong day-to-day operations, the company lacked a formal framework for continuous improvement. There were clear inefficiencies in line scheduling, production flow, and maintenance planning—but the internal team didn’t have the experience or structure to identify or address them effectively.
SPARQ360’s experienced team deploys a boots-on-the-ground approach and mediate operations and customer’s leadership teams allowing us to make unbiased, objective decisions based purely on what is best for our customers. Our team provided hands on guidance to warehouse staff, documented process changes and enabled inter-departmental communication to maximize their 3PL engagement. This was the missing link for this client.
The Strategy
SPARQ360 brought deep LEAN expertise to the table. We began by measuring and documenting the current state of operations—from raw material staging to final distribution. Then, using proven LEAN methodologies, we collaborated with the team to identify areas of waste, bottlenecks, and scheduling breakdowns.
Together, we designed practical, sustainable solutions grounded in real-world conditions and team capability.
The Implementation
- Conducted on-site assessments and value stream mapping
- Trained teams in LEAN thinking and CI principles
- Restructured the master production schedule (MPS) for better flow
- Optimized maintenance planning to reduce downtime
- Introduced standardized processes across making, packing, and distribution
Related service: Operational Excellence
The Results
- $250K+ in savings at a single manufacturing site
- Improved scheduling and uptime, boosting throughput
- Higher productivity and morale through team-driven improvements
- Embedded LEAN practices for ongoing efficiency gains
The existing team had the will—but not the tools. SPARQ360 delivered the structure, coaching, and experience needed to turn untapped potential into real, measurable progress.
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