Optimization of stuffed pie production
Moldova, 2018-2020
This project involved the optimization and re-engineering of an existing stuffed pie production process
to significantly increase daily output from 1,800 to almost 6,000 units per day, while preserving product quality and controlling investment costs.
The scope of work included process analysis, bottleneck identification, and line balancing, followed by targeted upgrades to forming, filling,
baking, and handling operations. Key improvements focused on automation of critical steps, improved synchronization between machines, and optimization
of product flow to eliminate downtime and manual handling inefficiencies.
Equipment settings and control parameters were fine-tuned to ensure consistent weight, uniform filling distribution, and stable product shape at higher speeds.
The production line was designed to maintain flexibility for different pie shapes and fillings, with quick changeovers and simplified cleaning procedures.
As a result of the optimization, the customer achieved a fourfold increase in production capacity, improved operational efficiency, reduced labor requirements,
and enhanced process stability—enabling the business to meet growing market demand with a reliable and cost-effective production solution.
"It was a long 2-year project but worth it totally. As a result of production optimization, we cut manual labor by 70%,
tripling the output without overtime, maintaining precise dough sheeting, filling and forming. Our workers shifted their attention more to preparation
activities and product quality checks. The next step is to engineer the manufacturing process for frozen product line, following the increasing demand
of the marker for of longer shelf-life product."
