Improved front-line management at BBQ producer chops $2.2M in annual costs, boosts yield a meaty 1.5 percent

This producer of precooked barbeque products needed to reduce costs and fatten margins while increasing throughput and yield. Its disconnected, ever-changing schedules created poor production flow, resource shortages and overbuilding. Overstaffing with temporary workers and overreliance on inaccurate forecasts drove up costs. The Powers Company examined and addressed every item affecting yield, equipped managers with training and tools, and aligned resources with production. The results? A satisfying $2.2 million in projected annual savings and a hearty 1.5 percent gain in yield.

Our client produces and distributes precooked, sauced, and ready-to-heat barbeque ribs, pork and chickens. The company’s 200-plus products generate annual revenues of $150 million using approximately 350 full-time and temporary employees. However, It needed to increase yield, improve flow and reduce costs throughout the production process to meet margins while optimizing a temporary labor pool.

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