In sports nutrition manufacturing, speed is non-negotiable. Science in Sport (SiS) is a UK-based manufacturer producing energy gels, bars and powders used by elite athletes and sports enthusiasts worldwide. Their Blackburn facility runs multiple production lines with same-day dispatch targets, leaving no room for wasted minutes or unexpected downtime.
For Shabaz Mahmood, Manufacturing and Engineering Manager at SiS, keeping pace means having instant insight into every part of production. When he stepped into his role, he inherited MaintMaster OEE and quickly saw how real-time data could help reduce inefficiencies, cut downtime and drive a culture focused on continuous improvement.
Breaking free from delayed data and hidden losses
Shabaz knew from past experience how damaging outdated, manual reporting could be. Paper logs and spreadsheets told only part of the story and always too late.
"With manual systems, you only got updates every hour. If something went wrong, you’d already lost the time."
At SiS, things were different. MaintMaster OEE was already live and the difference in visibility was immediate. MaintMaster OEE had replaced delayed, paper-based reporting with real-time visibility, allowing the team to track issues as they happen.
Real-time data fuels smarter, faster decision-making
MaintMaster OEE quickly became a key tool for the entire site. Instead of waiting for the next report, managers can make immediate calls to adjust processes, allocate resources or schedule maintenance.
"You’re either making product or you’re not - and you can see exactly why.“
Their data isn’t just for reporting, it’s now a planning tool. From real-time performance to monthly reviews, every level of data is easy to access. Insights from real-time data fuel both daily adjustments and longer-term planning at SiS.
Turning visibility into measurable production gains
Before MaintMaster OEE, changeovers regularly missed the 35-minute target. The software highlighted where time was being lost, allowing the team to focus their efforts precisely. Through targeted training and process reviews, changeover times dropped consistently to the 35-minute target and sometimes better.
"We did some training, reviewed the process and brought it down."
Another problem was harder to spot: micro-stops every few minutes due to a topping ingredient. MaintMaster OEE automatically tracks short micro-stops, like repeated 10–30 second interruptions, revealing problems that would otherwise go unnoticed.
A particular topping ingredient on certain protein bars was causing blockages every six minutes for about 10 seconds each time. Individually insignificant, these delays added up to substantial lost production over a week.
"We saw it was happening every six minutes for 10 seconds. Doesn’t sound much - but over the week, it added up."
MaintMaster OEE brought the pattern to light, allowing the team to solve the issue quickly. The fix was simple: avoid overfilling the pot holding the topping ingredient. This minor adjustment reduced stoppages by 40–50%.
Driving accountability and proactive problem-solving
As MaintMaster OEE became part of daily routines, shift managers started turning up with answers, not just problems. Morning meetings, once driven by management alone, have evolved into collaborative sessions.
Instead of simply announcing downtime figures, managers and operators discuss why issues happened and how to prevent them. Shabaz notes that this has shifted SiS’s culture from reactive problem-solving to proactive decision-making.
“Now they know they’ll be asked about OEE, so they find out the root cause first."
Every week, the engineering team reviews top losses from the previous seven days. Monthly, the data is shared with the wider production team and operators, helping everyone see where improvements are needed.
This regular review cycle builds accountability, as teams arrive at meetings ready not only to report issues but to suggest solutions. Management reviews are now solution-focused. Targets are realistic and agreed. If a shift misses the mark, the team knows to ask why and can see where to start.
Aligning engineering and production for strategic wins
Beyond individual shifts, MaintMaster OEE helps align production and engineering priorities across the site. With the software highlighting persistent issues, SiS can allocate engineering resources where they’ll have the biggest impact. It also supports bigger decisions, like when to stop a line for deeper repairs.
“We can prove it’s the right call. It helps justify downtime and plan for it.”
It’s not just a production tool. It’s a bridge between teams. If a particular fault worsens over weeks, Shabaz prefers to schedule planned downtime with the Maintenance team to address it properly rather than risking continued losses. This proactive approach protects output and prevents small problems from becoming major disruptions.
Maintaining operational control beyond the factory floor
An unexpected bonus has been browser-based access that allows Shabaz to stay connected even when off-site. He can monitor production from anywhere, home or away, ensuring instant visibility and zero delays.
“You don’t have to be on site to influence what’s happening.”
No delays. No waiting on reports. Just immediate visibility, wherever you are.
Tapping into untapped potential for continuous improvement
In just six months, SiS lifted OEE by 10% and Shabaz believes they’re only using a fraction of the system.
“We’re probably using one-eighth of the system - and it’s already this useful.”
Next on the list is turning on the automated reports function and freeing up even more time to focus on deeper analysis for additional improvements.
Building a future-ready manufacturing operation
Science in Sport’s experience shows how real-time OEE data, paired with clear ownership, can deliver fast gains and lasting culture change. MaintMaster OEE didn’t just improve output. It helped SiS shift from reacting to leading, giving their teams the confidence, clarity and control to keep performance on track.
“It’s our daily driver. It powers a lot of our decisions.”
In just six months, they’ve turned data into tangible gains, lifting OEE, shortening changeovers and reducing hidden losses. But perhaps the biggest result is cultural: a team that’s confident, connected and ready to keep improving. MaintMaster OEE has become more than a software tool, it’s part of how SiS stays competitive in a demanding industry where every minute counts.
Results at a glance
- OEE improved from 65% to 75% within six months
- Changeover time reduced by 5 minutes, consistently hitting 35-minute target
- Micro-stops cut by 40–50% with one corrective action
- Real-time visibility enables faster decisions and proactive maintenance
- Stronger collaboration between engineering and production
- Smarter resource planning driven by trend insights
“Using data to drive daily decisions - that’s what it’s about.”
For manufacturers focused on performance, MaintMaster OEE is helping turn insights into action and action into measurable results.
