Our last blog “Strategies for Reducing Inventory: Key Considerations by Type and Process” examined ways to reduce inventory in four key categories. In this shorter entry, we will describe two related concepts that beverage companies can use to optimize a production schedule on a single line as well as across lines.
In the beverage industry, demand is very dynamic making efficient production line management that maximizes output and minimizes downtime essential. Sistering and Cousining are innovative strategies that can enhance production efficiency; let’s dive into them to see how they can be used to streamline production operations.
Sistering: Scheduling Efficient Changeovers
Many beverage plants operate multiple production lines capable of handling different packaging formats on a particular line. The process of switching machinery between different package sizes, known as package changeover or swing, can be time-consuming and labor-intensive and often requires several hours of downtime. To reduce cost and inefficiencies of unneeded changeovers, the practice of Sistering produced products is extremely useful.
What is Sistering?
At a high level, sistering involves scheduling production runs for products that share similar packaging configurations back-to-back. For example, transitioning from a six-pack run to a twelve-pack run of the same beverage flavor typically requires minimal changeover time. By grouping “production sisters” to run sequentially, manufacturers can significantly reduce line downtime.
Benefits of Sistering
- Minimized Changeover Time: By running similar flavors consecutively, e.g., six-pack to twelve-pack to twenty-four-pack run, production lines can operate more efficiently. The only necessary adjustments are to change the packing set up, instead of the entire production line package setup.
- Balanced Production Scheduling: Production sistering leads to better inventory management. By producing to a common Days Supply (DS) inventory target across all sister items, production can be aligned to optimize production batches that will typically be needed in a cycle. For example, if a batch of Cola production is scheduled every five days, all sister items can receive a five-day allocation, reducing the need for off-cycle flavor production.
Cousining: Maximizing Resource Utilization
Cousining is an effective schedule grouping technique that helps beverage producers manage resource constraints, including batching tank availability and capacity. When multiple production lines share a syrup tank, it’s crucial to schedule runs for the same flavor across different lines in order to optimize the batching process.
What is Cousining?
Cousining takes the concept of Sistering a step further by grouping same-variety products that can be run on multiple production lines to be produced together. This is particularly useful when managing product groups that share a constraint but can be produced simultaneously.
Benefits of Cousining
- Enhanced Resource Management: By facilitating simultaneous same-flavor runs across lines, Cousining optimizes syrup tank batches, ensuring that production stays on a schedule in sync with batching requirements.
- Prioritized Scheduling: Cousin Groups can be prioritized based on the criticality of items within the group, ensuring that the most important varieties are produced when needed, without delays. Feedback of required batching based on Cousin group production can be provided to the Syrup room so that required ingredients are stocked per production requirement.
Summary
Sistering and Cousining are powerful strategies utilized in Areté’s Production Planning for optimizing production line efficiency in the beverage industry. By minimizing changeover times and maximizing resource utilization, utilizing both can lead to significant improvements in productivity and profitability. As you refine production processes, consider implementing these innovative approaches to help operations run more smoothly and effectively.
The next blog in this series, From Annual Vision to Daily Execution: A Guide to Supply Chain Planning, will explore 3 horizons of planning processes. Please subscribe to our blog to be notified as soon as the next in this series is available to you!
