Optimizing production efficiency in the consumer goods sector: a rapid, cost-effective approach

A manufacturing company in the consumer goods sector faced rising operational and maintenance costs due to inefficiencies in a critical production process. Their existing approach resulted in frequent disruptions, inconsistencies in product quality, and added complexity. A fast, cost-effective solution was needed to maintain performance while improving efficiency. 

The Challenges:  Unstable process conditions leading to variability in production and unplanned downtime. Operational inefficiencies increasing maintenance requirements and resource consumption. Supply chain and cost pressures necessitated a more streamlined, sustainable approach.

With only four weeks to identify viable alternatives, the company required a structured, results-driven strategy. 

The Solution: A Six-Step Rapid Innovation Process

A targeted methodology was applied to quickly evaluate and prioritize alternative solutions: 

	Identify Needs – We collaborated closely with the client to define precise operational, performance, and certification boundary conditions. By establishing 11 must-have criteria, we ensured a sharp focus on viable alternatives.
	Gauge the Landscape – Our strategic technical search went beyond chemical alternatives, mapping patents to potential partners and competitors to ensure a commercially viable, near-term solution.
	Network with Innovators – Collaborated with industry specialists and suppliers to assess and validate feasibility and innovation potential.
	Intelligent Selection – Using our proprietary screening methodology, we applied stringent technical filters, such as glass transition temperature, film-forming ability, and charge characteristics, to shortlist the most promising candidates.
	Test & Transition Readiness – We ensured seamless integration by aligning new chemistries with the client’s operational framework, setting the stage for future testing and accelerated implementation.
	Evaluate & Elevate – We delivered key findings, final recommendations, and a clear roadmap for implementation, while identifying additional refinements needed to optimize long-term success.

This structured approach ensured a low-risk, high-impact strategy for process improvement. 

The Impact: High-Value Insights Delivered in Four Weeks Multiple viable chemistries identified that aligned with production and quality goals. Additional promising candidates flagged for further research and long-term development. Project completed within four weeks, enabling a rapid transition to evaluation and implementation.

The company initiated next steps to trial the recommended alternatives, recognizing the product efficiency and strategic value of the approach. The outcome was a cost-saving, efficiency-driven solution that maintained product integrity while reducing operational complexity.

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