Müller Milk & Ingredients processes around a third of the UK’s daily milk. When it opened its £80 million Bridgwater site, the goal wasn’t just output. The team needed real-time clarity, faster decisions and full engagement across every shift. MaintMaster OEE became the tool that turned data into action daily - shaping behaviours, streamlining communication and enabling data-backed decisions at every level.
Formerly Robert Wiseman Dairies, Müller Milk & Ingredients, is one of the UK’s largest producers of fresh milk, cream and dairy ingredients. After being acquired by the Müller Group in 2012, it became part of the wider Müller UK & Ireland Group.
Embedding live performance data into daily routines to drive fast action and accountability
Its Bridgwater facility in Somerset is one of Europe’s most advanced dairy processing sites. Purpose-built for high-volume, lean operations, it combines automation and energy-efficient technologies to deliver consistent, large-scale production.
To meet these standards, the team needed tools that matched the site’s ambition. Bridgwater wasn’t just an investment in infrastructure, it was an opportunity to embed smarter ways of working from day one. And that meant making performance data available, usable and trusted across every shift.
Performance you can see...and act on
From day one, Bridgwater was designed for performance. But equipment alone isn’t enough. Teams needed a system that:
- Made data visible where decisions are made, on the floor
- Enabled real-time action from operators and engineers
- Supported alignment from line teams to leadership
Designed for fast-moving food production
The team chose MaintMaster OEE for its visual clarity, ease of use, and strong fit with high-speed food environments. It also integrated with their existing CMMS and systems, ensuring continuity.
“The reason we selected MaintMaster OEE was not just the software itself, but MaintMaster’s deep operational understanding and ability to make the data work on our terms”
This wasn’t about digital dashboards for the sake of appearance. It was about creating shared visibility, driving consistency across shifts and giving teams the confidence to act based on facts, not assumptions. MaintMaster delivered the transparency and responsiveness that the Bridgwater site needed to run at its full potential.
Turning real-time data into on-the-floor action
MaintMaster OEE was rolled out using a visual-first strategy:
- Live performance dashboards installed throughout the site
- Touchscreens on the factory floor for easy, accurate data input
- Automated data capture to reduce manual tasks and increase reliability
- Real-time event alerts sent to engineers and managers for quick action
Dashboards weren’t just hung on the walls, they became part of the team’s daily mindset. Line performance, downtime reasons and trend data were all readily available, prompting more focused conversations and quicker resolutions. By reducing data lag and manual reporting, teams could spend more time acting on insights instead of chasing them.
"Seeing our performance on the wall, in real time - that changes the conversation entirely."
The shift to real-time visibility also helped unlock collaboration. Whether it was a CI coordinator reviewing trends or a line operator spotting an issue mid-shift, everyone worked from the same data.
"Our CI and Ops teams speak the same language now, because they’re looking at the same live data."
Placing live data at the heart of every shift
Real-time data became part of the daily rhythm:
- Morning stand-ups used overnight data to guide priorities
- Shift handovers were built around live performance trends
- Engineering reviews focused on downtime and root causes
Operators no longer needed spreadsheets or reports, they could see exactly how their lines were performing in real time. This immediacy helped prevent issues from compounding over a shift, making interventions faster and more targeted.
Importantly, the system supported a proactive culture. Engineers didn’t wait for weekly reviews to identify problem assets. CI teams used the data to benchmark improvements and track project impact. And managers gained a clear overview of how each line and team was performing without needing to micromanage.
What Changed: Engagement, Insight and Control
- 10% OEE increase within the first 12 months
- A further 10% improvement in Year 2
- Full team engagement, from operators to engineering leads
- Performance data used daily in CI reviews, investigations and planning
- Faster response to issues, with reduced reliance on reactive firefighting
- Shared understanding of priorities across roles and shifts
“We didn’t want a system that just tracked our OEE. We wanted something that helped us act on issues in real-time.”
Creating a data driven culture, one shift at a time
At Bridgwater, performance data isn’t buried in spreadsheets or discussed after the fact. It’s live, visual, and part of every team’s day. By embedding MaintMaster OEE into their operational culture, Müller Milk & Ingredients created more than just a monitoring system. They built an environment moulded by their real-time OEE, one that enables fast decisions, proactive intervention and continuous improvement, driven by data teams trust.
From daily shift planning to long-term CI tracking, the system continues to help Bridgwater evolve. Teams are more aligned, actions more timely and improvement efforts backed by facts. With MaintMaster OEE, performance isn’t just managed. It’s made visible, actionable and part of how the site works during every shift and every day.
