Optimize the efficiency of Cargill’s maintenance organization

Cargill provides food, agriculture, financial & industrial products and services to the world. Together with farmers, customers, governments and communities, we help people thrive by applying our insights and 150 years of experience. We have 155,000 employees in 68 countries who are committed to feeding the world in a responsible way, reducing environmental impact and improving the communities where we live and work.

At the plants in Sas van Gent and Bergen op Zoom Cargill processes wheat and corn into starches, starches derivates, wheat proteins and glucose. Main customers for this products are in the food industry, including confectioners, brewers, beverage makers, dairies and bakeries..

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Project definition and goals

The goal of the project was provide analysis data describing the actual situation in work preparation and execution for maintenance activities at Cargill Sas van Gent and Bergen op Zoom. The objective is to optimize the efficiency of Cargill’s maintenance organization and to set -up a solid plan to reduce maintenance costs.

Project approach

PDM was asked to identify:

  • The improvement potential in efficiency in both work preparation and execution
  • The causes of the loss in productivity.
  • PDM was also asked to determine the required actions to recover the productivity losses.

For this PDM applied a three-step approach:

  • A statistical analysis of the existing data at Cargill (= how do people manage)
  • Process and system mapping (= how do people think they are working)
  • On the floor observations (= how do people really work)

Project results

  • The Hands on Tool Time-study revealed a possible cost saving of 22%.
  • A list of actions was proposed to Cargill to optimize work preparation and execution for maintenance activities at both sites.


Wim Dokter
Continuous Improvement Lead, Cargill

PDM was asked to identify improvement potential in work preparation and execution, to identify causes of productivity losses and to determine the required actions in order to recover the productivity losses. Cargill is very satisfied with the results so far and recommends PDM to anybody who need to execute an analysis based upon the needs and the requirements of an organization.



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