Plant Consulting
Diagnostics, layout and control for measurably higher yield and stable operations
Our approach
We work in short phases with clear targets, for example reduce smoking losses or halve changeover time, typically lasting 1 to 2 weeks. First the as-is state of each line is measured. Then bottlenecks, losses and quality deviations are prioritised by cause, frequency and impact. Solutions are verified as small experiments on the floor and only then converted into standards. In this way bottlenecks, losses and quality deviations are prioritised by cause, frequency and impact. Solutions are verified as small experiments on the floor and only then converted into standards.
Outcomes
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OEE increases, losses decrease
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Process windows are maintained
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Changeover times become shorter
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Specifications remain consistent
Operational framework
Diagnostics
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Losses: yield, giveaway, rework, downtime
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Takt and balance: is work distribution per station appropriate
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Quality points: texture, moisture, temperature, weight
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Traceability: are batches cleanly trackable
Changeovers
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List all changeover steps and measure time per step
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Define sequence and responsibilities
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Create checklists and post at workstations
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Goal: stable changeover with steady output
Typical project flow
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Phase 1: capture, goals, measurement points
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Phase 2: implement fast measures with immediate effect
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Phase 3: create standards and documents
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Phase 4: stabilise and hand over to the teams
Layout & material flow
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Keep paths short and set buffers sensibly
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Arrange hygiene areas and airlocks appropriately for safe flow and access
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Secure the cold chain from intake to dispatch
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Set line balance to achieve the target output per shift
Quality & specification
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Embed the inspection plan in the material flow
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Capture measurement data automatically where possible
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Map release and hold with batch reference
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Trace deviations back to root cause
What you receive
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Action plan with deadlines, owners and target values
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Visualisations for shop floor and control room
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Standard documents for layout, cleaning and inspection plan
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KPI pack for shift, line and management
Control and KPIs
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Make the daily overview for OEE and losses visible for all operators
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Handle deviations with a clear response plan
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Integrate CCP and CIP values into line control
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Provide dashboards for shift, team and management
Organisation & training
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Clarify roles per line and secure handovers
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Start of shift with target values and bottleneck notes
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Short on the job trainings with measurable effect
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Audit ready through clean records
Reference topics
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Bacon and hams with stable yield
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Sausages and MDM with defined texture
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Biltong and droëwors with controlled drying profile
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Catering bacon with minimal cooking shrinkage
CONSULTING FOCUSES
Plant Consulting
We audit and improve every layer of the plant, including formulations, deboning workflows, data models and real-time KPIs.
Freezer Stock Audits
Map cold store inventory. Detect stuck and ageing items. Plan repurpose, relabel, reformulate or write off. Release cash.
In-Process Cleaning Audit
Optimise sanitation. Boost food safety. Cut downtime and labour. Ensure consistent cleaning and verification.
Yield & Profit Audit
Assess gross profit potential by line. Identify underpriced items and mix effects. Propose targeted reformulations. Unlock hidden revenue.
Management Dashboards
Visualise yield, loss and OEE in real time. Align views to the business model. Keep factory state continuously readable.
Yield Optimisation
Check contribution by line and SKU. Evaluate formulations. Propose reformulations. Unlock hidden revenue and pricing potential opportunities.
Procedure & SOP Validation
Review critical SOPs and procedures. Standardise language and steps. Validate with cross functional teams. Increase audit readiness & process consistency.
Processing Line Audits
From intake to packaging identify bottlenecks, imbalance, quality risks and under utilisation. Deliver a prioritised action plan.
Systems & Data Design
Define data structures. Harmonise ERP and Excel sources. Provide dashboards and tools. Activate AI assisted analytics as needed.
Strategic Guidance
Analyse expansions and re tooling. Model scenarios. Orchestrate implementation in clear steps. Measure outcomes.
From Layout to Line
Eben on site, from the ground up
We support plants from first foundations to live production. Layout, material flow and process windows are planned on site and later validated at the line. The goal is short paths, clear standards and measurably stable operations. In 2018 Eben stood at the start of construction of West Africa’s largest fully functional meat plant, planning layout, material flow and process windows from day one and later verifying them on the line.