UCC transforming planned maintenance through operational excellence
19th May 2026 | 2 min read
The Challenge
The Ueshima Coffee Company (UCC) operates a UK-based Planned Maintenance (PM) facility dedicated to coffee excellence and customer service. A requirement to move its entire operations to a new site later in 2026 was seen as an opportunity to rethink its PM operating model in order to improve quality, raise productivity, reduce lead times all within a restricted footprint.
UCC knew their current batch processing operating model had created sub-optimal workflows but previous attempts to move to the optimal single piece flow model now required assistance to bring to a successful conclusion.
Seeking a rapid, sustainable transformation, UCC partnered with Unipart to leverage their Operational Performance Improvement (OPI) methodology and achieve single piece flow ahead of the Q3 relocation.
The Solution
Working collaboratively, Unipart deployed the Engage, Diagnose, and Design & Test steps of their proprietary 6-step OPI model, transforming the facility’s vision from traditional batching to single-piece flow in under six weeks.
To ensure deep engagement and buy-in, Unipart collaborated directly with technicians, team leaders, quality control and management. Together, they redesigned ten production lines based on principles of flow and pull whilst also positioning the team leaders on the shop floor for clear operational oversight.
Advanced CAD visualisation ensured the new layout would fit the upcoming facility’s restricted footprint, while a future-state flythrough video aided wider communication from the shop floor through to the boardroom.
The Impact
The partnership successfully created a future-state “production line” facility based on the space constraints of the new site in less than 30 days. While the 10 production lines await full physical implementation, the design phase has identified significant potential productivity uplifts and opportunities, which were validated by UCC Operational Leadership:
- Estimated 22% overall productivity uplift across the facility
- Potential productivity uplifts identified in specific production lines; 21% for Boiler production, 26% for Tray production, and 16% for Hydraulics
- The new flow-based design offers the opportunity to train new Technicians on simple tasks in just 2 weeks, down from several months
- The design confirms that the workshop can function effectively within a smaller footprint, meeting the relocation requirements for the Q3 2026 deadline
- The integration of a dedicated Quality Area and Pre-Delivery Inspection (PDI) zone within the flow ensures quality is built into the process.
As UCC completes the Design & Test phase for each of 10 production lines, we look forward to supporting them through the final three phases of their OPI transformation: Implementation, Sustain and Continuous Improvement.
