FMCG Project Case Study 1 – Packaging Line Upgrade & Automation

Client Challenge

A major FMCG manufacturer needed to upgrade an existing packaging line to increase throughput and introduce automation.
The project had multiple constraints:

• Tight timeline to align with seasonal product launches.

• Need to integrate new technology with legacy equipment.

• Maintain production with minimal downtime.

My Role

• Created a detailed scope of work and URS, ensuring suppliers understood both technical and operational requirements.

• Managed vendor selection and negotiation, leveraging my network to find the right partners.

• Oversaw installation planning, including civils works for new equipment and utility connections.

• Implemented strict compliance controls, covering GMP, ATEX, and safety regulations.

• Provided hands-on site supervision, ensuring contractors adhered to quality and safety standards.

Result

• Line upgraded and commissioned two weeks ahead of schedule.

• Achieved 20% increase in line efficiency with minimal disruption to production.

• Reduced waste and improved product quality through enhanced automation.

• Supplied comprehensive documentation for training and compliance purposes.

“Dave’s ability to translate our vision into clear supplier specifications saved time and prevented costly mistakes.”
— Engineering Manager, FMCG Manufacturer

Case Study 2 – URS & Documentation Support for SME

Client Challenge

A medium-sized food manufacturer needed to purchase a new piece of production equipment.
They lacked internal engineering resources to create technical documentation, such as a URS, that suppliers could quote against.
Without this, they risked:

• Misunderstandings with suppliers.

• Unexpected costs and scope changes.

• Non-compliance with safety and regulatory standards.

My Role

• Engaged on a fixed-fee work package to quickly deliver the necessary documentation.

• Worked closely with the client to capture operational needs, budget constraints, and compliance requirements.

• Developed a clear, structured URS that translated the client’s expectations into supplier-ready technical specifications.

• Provided additional guidance on potential suppliers and project planning.

Result

• Client received three comparable supplier proposals based on a consistent scope.

• Avoided potential overspend and scope creep by clearly defining requirements upfront.

• Project executed smoothly, with full compliance documentation in place.

• Client retained the documentation for use in future expansions.

“Dave’s input gave us confidence and clarity. We went to suppliers knowing exactly what to ask for, and it saved us time and money.”
— Managing Director, SME Food Manufacturer