Established global dairy industry leader calls on POWERS to meet ROI from $150 million investment in new processing plant. Our team jumped in to immediately uncover production challenges and deliver a massive performance boost.
Founded over eighty years ago, our Midwest-based client is one of the largest dairy producers in the world, producing 1 billion pounds of wholesome, high-quality cheeses annually for retail brands and the foodservice industry.
This global dairy industry powerhouse built a new, $150 million plant to increase production capacity and meet surging demand.
However, to meet the ROI goals of management, the new plant had to package 36,000 pounds of product per hour.
As a result, the POWERS team was brought on for an 8-week Sprint to improve plant performance and provide the roadmap to reach ROI performance goals.
Our team worked quickly with frontline leadership and the plant workforce to uncover the production bottlenecks hampering performance.
As always, we looked holistically at the business and examined the systems, processes, and behaviors that will maximize capacity most efficiently.
We found a lack of defined processes to optimize performance and efficiency. There were no checklists for personnel to follow at critical points like start-up and shutdown.
Beyond process issues, our team found many operators and line personnel without proper job-function training.