In a market pressured by rising costs and growing competition, Lactalis has embraced Lean as a strategic tool. Álvaro Mardones, Lean Manager at the Villarrobledo plant, shares how they’ve professionalised the system and engaged the entire workforce—with the support of SGS PRODUCTIVITY.
Lean as a driver in an established company
Lactalis Group is the world’s leading dairy group. In Spain, it operates several plants producing milk, yoghurt, desserts and cheese. In the cheese segment, the company has developed its own continuous improvement system—Lean Lactalis—implemented in its facilities in Peñafiel, Zamora and Villarrobledo.
As Álvaro Mardones explains, the goal was clear: remain competitive without compromising quality, even in a highly cost-pressured environment. To achieve that, they needed to standardise processes, break old habits, and apply a methodology that helps people improve their daily work in a structured way.
A system that evolves with people
The journey began in Peñafiel, was consolidated in Zamora, and reached maturity at the Villarrobledo plant—one of the largest and most complex in the group. The challenge was significant: involve everyone, challenge the “we’ve always done it this way” mindset, and build a new work culture focused on ongoing improvement.
According to Álvaro, the biggest success has been achieving genuine belief in Lean. People understand it, apply it, and in some cases, even use its principles in their personal lives. “I’ve seen people apply Lean at home with their families—that’s when you know they’ve truly embraced it,” he says.
Productivity, data and motivation
Results have been significant. Productivity has improved, middle managers now work with clear KPIs, and management has become more professional. But beyond the numbers, the shift in mindset stands out—more motivation, more ownership, and an environment where idea
Active listening has been essential. “When people feel heard, they engage. And when they’re motivated, everything becomes easier,” says Álvaro. This approach has transformed the role of supervisors, who now lead by example and proximity.
The value of SGS PRODUCTIVITY
Lactalis has worked with several SGS PRODUCTIVITY consultants throughout this process, and Álvaro notes that each one brought something valuable. “Some had a strong people focus, others were more technical or data-driven—but all of them helped us grow and see Lean from different perspectives.”
This adaptability, hands-on approach and trust-based collaboration have been key to consolidating the system. “With SGS, improvement is a sure bet,” he concludes.
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