Reined-in giveaway, rework and M&R costs help meats processor recoup $70 million over three years

The Value-Added Meats division of this $135 billion global leader needed to reduce giveaway, labor and M&R costs while boosting productivity and yield. The Powers Company taught supervisors to balance production lines; instituted startup preventive maintenance; developed leadership skills; and aligned resources with volume demands. We also put controls in place to minimize rework, waste and giveaway. The takeaway? Over $70 million in total savings, a 15-19 percent efficiency gain and a 2 percent yield increase.

Our client, part of a U.S.-based global food conglomerate, supports foodservice and retail customers with raw and ready-to-eat (RTE) further processing of meats, hams and poultry. The ValueAdded Meats organization sought to improve financial performance while maintaining product safety. Its leaders wanted to align planning and scheduling with customer requirements, and schedule production properly to minimize bottlenecks and other issues. They also needed outside resources to expedite, internalize and sustain continuous improvement.

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