This meat packing industry leader faced market demand that strained long-standing operational systems, processes, and behaviors that left them unable to satisfy customers. Our team helped enhance scheduling, capacity, frontline leadership skills, and more. The results? Meaty productivity gains and $5.8 million in annual savings.
Our client has deep roots and well-established brands in the meat processing and packing industry. They are renowned for their high-quality food products that combine four key components; top-quality meat, an expert blend of spices, natural wood smoking, and people who care about delivering quality food.
This time-tested recipe for success and established company traditions have helped them create delicious products and a thriving organization actively involved in its community. Like many companies in the food industry however, demand is skyrocketing yet unpredictable, placing strains on, and uncovering pre-existing operational weaknesses.
This stalwart company, behind some of the most beloved brands in their market space, found itself facing a need for increased throughput to satisfy customer orders and gain market share.
Management struggled to scale with paradigms that had worked for years, relying on systems, processes, and behaviors as ‘they used to do.’ The company also faced a generational management transition, as managers and frontline leaders who had been there for 20-plus years were getting ready to retire and take their years of experience with them.
With the holiday season quickly approaching, production needed to satisfy the most customers and increase yield, which had been in a steady decline for 75 weeks. As a result, lost Time was nearly equal to production time.
Additionally, no One Point lessons learned existed at the execution level. Instead, a ‘whatever it takes to get it out the door’ fire-fighting culture existed across the organization, from the top floor to the shop floor.