Using the Theory of Constraints to triple sales and production in the dairy food and drink industry

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Charalambides Christis

Using the Theory of Constraints to triple sales and production in the dairy food and drink industry

Dairy business is a very complicated food sector. Someone needs to balance quality, freshness, shelf life, taste and responsiveness in order to lead the market.

On the top of that regulations, high seasonality and fierce competition force dairy companies to search for methodologies to guide them into the future. 

Halloumi Cheese is Cyprus traditional cheese. It is being sold all over the world and the market demand keeps expanding with an organic growth at a rate of 25% per year.

Charalambides Christis is the largest dairy company in Cyprus with a turnover of more than 100 million euros and with a workforce of 600 people. It is the only company in Cyprus which produces a number of different categories of dairy products such as pasteurised milk, yoghurts, cheeses and UHT products.

The company was operating at maximum capacity for years but it couldn’t satisfy the increasing demand. This trend forced the board of directors to decide to expand the capacity of the cheese plant.

This presentation covers the implementation of the Drum Buffer Rope and how the company managed to triple production flow with minimum investments at the existing manufacturing space and forming the largest halloumi manufacturing plant in the world.

The received the Exports Awards 2017 in december 2017.  

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Spyros Bonatsos – Bio

Spyros Bonatsos currently is the Exports Manager of the biggest dairy in Cyprus, Charalambides Christis. Through his career he went through different managerial functions such as management of the technical department (7 years), management of the Supply Chain and logistics departments (8 years) and for 4 years he managed the manufacturing operations of the whole dairy.

He holds a BSc in Electrical Engineering from the Regional Technical College, Waterford, a PgDp from University of Abertay Dundee, a MBA from the Cyprus Institute of Marketing and a Master Degree in Engineering and Technology Management from the Washington State University, currently he is a PhD candidate at the University of Strasbourg researching TOC effectiveness in healthcare. He holds a post-graduate certificate in TOC and a post-graduate certificate in systems engineering by the Washington State University additionally he is certified in the logical Thinking Process by Bill Dettmer.


About Marris Consulting

Marris Consulting is an industry consulting and training company specialized in the Theory of Constraints (ToC) and Critical Chain Project Management. We focus on improving the performance of manufacturing and process industries by using Constraints Management combined with Lean and Six Sigma. To boost project performance, we also use Critical Chain Project Management (CCPM), which we sometimes combine with Lean Engineering. Our 2-day performance audits, our performance consulting services and our project management, Lean, ToC & CCPM training by our industry consultants offer a wide range of solutions to help our clients around the world reach the highest possible levels of performance.

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