The challenge

A leading beverage manufacturer with more than a century of operating experience sought to elevate operational excellence across its facilities. In 2018, the organization began its continuous improvement journey with Adonis Partners, initially piloting the effort at a single plant.

While improvement opportunities were evident, leadership needed a structured approach to build internal capability, sustain results, and expand continuous improvement across the enterprise.

The continuous improvement capability-building approach

Adonis Partners began by identifying four priority opportunity areas: quality improvement, scrap reduction, machine efficiency (OEE), and labor productivity. To address these areas, project leaders and key team members were trained in Lean Six Sigma methodologies at the Yellow and Green Belt levels.

Adonis’ lead consultant coached project leaders through structured problem-solving techniques and supported execution of high-impact improvement projects. This hands-on approach ensured that Lean Six Sigma tools were applied directly to real operational challenges, while participants earned industry-recognized certifications.

Success at the initial plant provided a blueprint for expansion. The continuous improvement model was then rolled out across additional sites, creating a consistent approach to identifying, prioritizing, and executing improvement initiatives company-wide.

The impact

The transformation delivered significant and measurable results. The organization achieved $6 million in EBITDA improvement, identified $6.9 million in additional savings opportunities, and trained more than 300 employees in Lean Six Sigma methodologies.

Dedicated continuous improvement leaders were established at each plant, embedding problem-solving capability into daily operations. As a result, employees became more engaged and proactive, fostering a culture where teams are equipped and motivated to drive ongoing value and operational excellence.