The Company
The Miller Brewing Company is the second largest brewery in the US and the third largest worldwide. Owned by Philip Morris, the 140-year old business has a progressive operating and marketing strategy which has contributed to Miller’s reputation for innovation.
Company Vision
Miller built its first plant in 1983 in Trenton, Ohio but did not start production due to poor market conditions until 1990 when the management decided to commission the plant and introduce innovative management concepts. The aim was to turn the Trenton plant into the brewery with the highest productivity in the world. The strategy was to develop and implement a unique company philosophy that combines a variety of modern management concepts like Just-in-Time, Total Quality Management, Total Productive Maintenance and self directed workgroups based on the TEAM CONCEPT™ methodologies.
Excellent Results
After only four years the Trenton plant was one of the most successful breweries in the world. It has the same production output as the other six Miller breweries, but with only half the staff and the lowest production cost per hectolitre of beer. The innovative organisational model has become a Miller Brewing brand and is an outstanding marketing tool.
`Trenton´ is now a synonym for the `Miller Brewing Company´ and vice versa.
Optimal Plant Utilisation
The brewing plant in Trenton is a 24 hour 7 day a week operation that is covered by three nine hour shifts a day. The first hour of each shift is set aside for communication and paid separately. The teams determine the staffing for each shift independently.
Successful Teamwork
All maintenance employees are organised in teams of 6 to 19 members. The majority of teams are usually on the same shift and only seven out of the total 33 teams work flexible or floating shifts. The members of each team interface with the production process at different stages, e.g. maintenance, procurement, logistics. The tasks carried out by foremen and managers are significantly different from their traditional function.
The `Star System´
The unique `Star System´ is a method to control teamwork, the budgeting process and to measure actual performance. It encompasses the following functions of independently working teams: administration, HR affairs, quality management, safety, maintenance and continuous performance improvement. One team member is responsible for each area. The system’s symbolic name stands for clearly-defined responsibilities for each individual and the optimal coordination of all work processes within a team.
Open Communication Structure
The Miller Brewing Company has a communication structure that supports the successful work of self-directed work groups. Every shift starts with a team meeting and the workers from all three shifts meet once a week. Employees from the administrative and management functions follow the same meeting pattern. Production is stopped once a year to allow all employees to attend a company conference at which annual production results are reviewed and detailed information about new trends and targets is provided.
Success is down to the Employees
Employees identify with their company and are therefore highly motivated. Teamwork at Trenton is based on the TEAM CONCEPTS™ methodology and has been a great success. The Miller Brewing Company invests in extensive training programmes and each employee receives at least 80 hours of training every year. About 50% of this time is spent on the development of technical skills, the remainder on social and organisational aspects. New employees undergo extensive training in their first year at Miller Brewing Company with their training covering subjects such as company philosophy, quality awareness, customer focus and group dynamics.
Team Concept™ Training Method
Teamwork is a method of organising work and contributes to the management of quality. It is commonly accepted that quality can not be enforced from the top but only achieved by individuals taking responsibility for the quality of a process.
T.A. Cook has developed the TEAM CONCEPT™ training program for the successful application of teamwork in most types of organisations. There are 20 stand-alone training modules with each module based upon practical exercises and examples. These modules provide the foundation for the successful implementation of self directed workgroups.
Putting Theory into Practice
The Miller Brewing Company is one of many renowned organisations in the world that have successfully used the TEAM CONCEPT™ training programme to implement teamwork- based organisational change.
T.A. Cook Consultants has 15 years of experience in the implementation of teamwork and with TEAM CONCEPT™, offers a tool that supports the change process and greatly enhances the chances of success.
Further information supplied upon request.
For more information contact:
Rupert Clark
Marketing Manager
Direct: +44 (0) 1183 260 229
Mobile: +44 (0) 7792 926 696
r.clark@tacook.com |
Miller Brewing (Case Study) »