DAVA Foods Estonia

Efficiency without additional resources – a new level of intralogistics.

Client: DAVA Foods Estonia
Industry: Company specializing in egg production and processing
Project duration: 8 working days, 5 of them on-site in Estonia
Services: WorkStudy 360® development project
Results: +4.5 million more eggs in annual throughput, equivalent to approx. €450,000 in additional revenue (€0.10/egg), and 1,043 hours of labor time saved

“The joint development work laid the foundation for doing more in Estonia going forward smarter, not harder.”

What was done?

WorkStudy 360® development project

Project duration: 8 working days, 4 of them on-site in Estonia

Methods used:

Simulation of improvement proposals & investment calculations
Observational study
MOST (Maynard Operation Sequence Technique) motion analysis
Employee interviews
Layout and material flow analysis

Areas for improvement:

End-to-end production process: from receiving to dispatch
Balancing workload
Improving layout and space utilization
Mapping automation opportunities
KPI framework and bonus model

Starting point

Production volumes had increased, but intralogistics and packing operations hadn’t kept up. Space was tight, workloads were unevenly distributed, automation wasn’t being utilized, and there were no clear performance metrics in place. The goal was to find practical, concrete solutions that would enable growth without adding headcount.

Outcome

The project identified an improvement roadmap that enables increasing production capacity by up to 4.5 million eggs per year without adding headcount—equivalent to approximately €450,000 in additional revenue. At the same time, it delivered 1,043 hours of labor time savings and provided recommendations for job rotation, automation (AGVs, robotic packers), two layout alternatives, and a three-tier performance bonus model.

The project also highlighted several safety gaps (wet floors, missing safety shoes, limited visibility at intersections), for which improvement proposals were created.

Overall, the collaboration gave DAVA Foods Estonia a concrete, measurable direction to develop production smarter, not harder.