Insights into Excellence: Visit to Princes Foods Manufacturing Site, Cardiff
Our recent visit to the Princes Foods Manufacturing Site in Cardiff offered a powerful glimpse into what operational excellence looks like when culture, capability, and continuous improvement come together. The site, which manufactures and packages juice cartons for major UK supermarkets, is a shining example of how Lean thinking and people development can drive performance at scale.
A Culture of Continuous Improvement
From the moment we stepped on site, it was clear that Princes Cardiff is a site on the rise — deploying new technologies, embracing change, and nurturing a deeply engaged workforce. Operators were not only aware of the site’s goals but were genuinely enthusiastic about their contribution to achieving them.
A new Obeya Room now anchors their Tier 2 and Tier 3 meetings, providing a dedicated space for structured discussion on performance, improvement, and problem-solving. The atmosphere was energetic, transparent, and grounded in data-driven dialogue.
Operational Excellence & Lean Deployment
Princes’ Operational Excellence and Lean Deployment Program is delivering impressive results. Their academy program has trained 277 people across 22 cohorts, completing 112 Lighthouse Projects and achieving over £21 million in savings in just four years.
A key takeaway from the Lighthouse Projects was the use of Kata coaching and the reframing of problem statements — practical tools that ensure problems are approached with clarity and curiosity. This disciplined problem-solving mindset was evident at every level of the organisation.
Developing Capability, Not Just Training
One phrase that resonated throughout the visit was that “Princes doesn’t train people — they develop capability.” This subtle but significant distinction highlights a mature understanding of learning and improvement.
Through a comprehensive knowledge transfer program, the site measures capability via skills matrices and training hours, ensuring that learning is embedded and progress is measurable. The focus is on empowerment — equipping people to think, solve, and lead.
Frameworks that Drive Excellence
Princes’ Operating Framework (POS) is firmly built on Lean principles, mirroring the structure of the Toyota Production System. The site has also integrated elements of the Shingo Model, ensuring equal attention is paid to culture, behaviours, and systems thinking.
The site’s Opex philosophy — People + Process = Performance — is more than a slogan; it’s visible in every conversation, visual board, and coaching session. The robustness of their problem-solving framework and governance process ensures alignment between strategy and daily activity.
Performance and Recognition
Performance across the Princes Group is measured through a comprehensive assessment program, grading sites Bronze, Silver, or Gold — creating a healthy sense of competition and continuous improvement.
Metrics include:
- Assessment results
- SQCDP performance
- Knowledge transfer and training hours
This structured approach ensures that excellence is measurable, repeatable, and scalable.
Early Equipment Management and New Technology
The Cardiff site is also leading in Early Equipment Management and the deployment of new packaging machinery, showcasing how investment in technology complements process discipline and people capability. Their approach to built-in quality reinforces prevention over detection, ensuring reliability and consistency across operations.
Leadership and Collaboration
A huge thank you to Joe Clayton, Jayne Jones, and Andy Sargent for hosting and sharing their journey. Andy’s presentation on the Opex Strategy and deployment approach, along with Joe’s insights into built-in quality and Lean deployment, provided excellent clarity on how strategy translates into shopfloor reality.
Their leadership exemplifies how structured governance, coaching, and engagement can transform performance and culture.
Visitor Reflections
Feedback from attendees captured the essence of the visit:
- “Really interesting and a lot of useful information that is transferable.”
- “Very rewarding and has provided lightbulb moments.”
- “Really great perspectives and conversations.”
- “Good to see a different industry with similar processes.”
- “Excellent data, process and organisation — great content and host.”
Key Takeaways and Actions
The visit inspired several AHA moments and actionable insights that participants will take forward within their own teams and organisations:
- Review Kata best practice techniques
- Establish or refine the structure of Lean and its supporting pillars
- Strengthen CI (Continuous Improvement) management and consistency
- Enhance standardisation of processes
- Implement or improve SOP boards
- Develop visual, proactive performance boards
- Reinforce food hygiene standards and their practical application
- Explore an academy-style approach to develop internal capability
- Promote visible leadership and daily engagement
- Maintain a consistent drumbeat of CI activity
- Ensure clear alignment between site goals and improvement projects
- Drive consistency through coaching and process confirmation
- Celebrate and encourage small, incremental changes
- Revisit or define the organisation’s Lean strategy
- Prioritise quality over speed in decision-making and process design
- Consider the 8 Pillars of Excellence as a structured improvement framework
Looking Ahead
Princes Cardiff is an inspiring example of a site that is leaning into excellence, embracing change, and building the foundations for sustainable success. We look forward to revisiting in 2026 to see how their journey continues to evolve.
Thank you to the entire team for your openness, energy, and commitment to excellence.
Our next visit, for more information or to book CLICK HERE
About Onsite Insights
Established in 2004, the Onsite Insights visit program exists to encourage the sharing of innovation and best practice between companies. This is achieved through a series of one day visits to award winning companies where visitors get to see best practice in action. No theory, no text book, just what works and why from organizations that have achieved success.
For More Information contact:
Jim Brydon
Programme Manager
Onsite Insights
Jim.Brydon@sapartners.com