Bolletje B.V. Almelo - NL:

Improving on the old, preparing for the new

Bolletje B.V. is a Dutch “brand-A” manufacturer of breads, bread substitutes and pastry products. Until recently a family-owned business dating back to the late 19th century, its famous “beschuit” (rusks) has made the company a household name in the Netherlands. The company’s main manufacturing site and bakery is in the eastern city of Almelo.

Operations Manager Henri Wolters saw the need to transform Bolletje B.V. into a modern manufacturer, and approached ARV Group to assist in drafting and implementing a concrete plan of improvement. Efficiencies in line productivity and maintenance were to play a major role in helping the company take the hurdle into the 21st century.

Establishing ownership

The case study drafted by the Group, which focused on the production process, process technology, the organization and the quality and organization of the workforce, was approved. Special emphasis was laid on improving organizational efficiency and line yield and establishing “ownership” on the part of employees and first-line management.

In the course of the nine-month implementation period, some twenty-five specific improvements were realized. These included measures that effectively helped to cut waste by reducing breakdowns and rejects on the packaging lines while increasing line speed, the introduction of training programs for operators and technicians, the monitoring and reduction of costs with the use of continuous improvement process (WCM/Lean), and the adaptation of operator capacity in accordance with seasonal peaks and off-peaks.

A steerable organization

Despite an unexpected change from a three-shift to a five-shift system due to a needed renovation, and with only minor investments in the plant’s less-than-modern infrastructure, this systematic and results-oriented approach made it possible to improve productivity over all lines by c. 2,000 hours. Along with Bolletje management, ARV Group applied its expertise to help the company transform itself into a steerable organization with empowered employees, and to help imbed a performance management system and continuous improvement processes that would benefit both production and the maintenance organization.

By the end of the implementation, the original goal of € 650k in structural savings was surpassed for a final estimate of € 1 million.

Henri Wolters, Operations Manager: "ARV Group helped Bolletje change from a pure cost focus to a results-oriented organization. Today we’re better prepared for the future, and the change is a lasting one".

Jeroen Spanjer, Production Manager: "The improvements made with regard to waste on the packaging lines, smarter outsourcing and a new reporting structure have not only boosted the company’s financial results, but have also been a source of inspiration for our people."