Powers Leads 26% Capacity Utilization Turnaround at Partner’s Newly Acquired Plant-Based Meat Processing Site

Project Overview

Recently, a disruptor and innovator in plant-based meat products for the retail and foodservice sectors partnered with POWERS to turn around flagging capacity utilization at a newly acquired site. They aimed to transition the leadership team, labor force, systems, and processes to their own methods and drastically improve the site’s production, which stood at a lackluster 46% capacity utilization. 

Our Partner’s acquisition of the “mom & pop shop” came with the entire labor and management force. Unfortunately, the existing leadership and workforce culture was out of step with new ownership and lagged significantly behind industry standards for operational excellence. 

From a Culture Performance Management perspective, we found engagement on the shop floor to be minimal, expectations poorly communicated, inadequate training, and leadership struggling to come together as a team to solve issues. The site leadership struggled to develop a “one team” approach to problem-solving.

Operationally, the site suffered from:

  • No MOS (Management Operating System)
  • No formalized processes for production, maintenance, logistics, and commercialization.
  • Lack of objective data fueling unproductive decision-making.
  • High labor turnover
  • Lack of leadership, operator, and mechanical skills training
  • Massive product waste
  • Poorly managed materials and ingredients for on-demand production
  • An “emergency” maintenance culture through poor supervision, scheduling, and prioritizing

Beyond the existing systems, processes, and cultural issues, the changes from the acquisition itself and our Partner’s intense growth compounded the challenges. 

Performance Results

POWERS leads a 26% Capacity Utilization turnaround for leading innovator and disruptor in plant-based meat products for the retail and foodservice industries.

Click here to download a PDF copy

Save it to read later, or share with a colleague

Read More Case Studies

Powers Partners with World-Class Meat Processor For Huge Performance Gains: Productivity Up 47%, Yield Up .41%!

POWERS Leads Production and Maintenance Transformation of World-Class, Family-Owned Meat Processor Looking to Improve Throughput and Capitalize on Massive Demand. Project Overview POWERS partnered with a world-class, 7th generation family-owned and operated meat processing company that uses only real, natural...

POWERS Adds $1.2 Million to Wind Tower Manufacturer’s Bottom Line, Slashing Overtime by 50% While Improving Productivity and Efficiency.

POWERS partnered with an industry-leading wind tower manufacturer to identify and quantify opportunities to improve the systems, processes, and leadership behaviors aligned with their previously established cultural values. Project Overview POWERS partnered with an industry-leading wind tower manufacturer to improve...

Powers Boosts On-Time Performance by a Staggering 59% For Defense Industry Make-To-Order Manufacturer

POWERS Drives Operational and Cultural Sea Change for Defense Industry Manufacturer Resulting in Staggering Performance Improvements Project Overview Faced with a competitive bidding environment, disrupted supply chains, and little predictability within its manufacturing department, our Partner, a Make-to-Order Manufacturer in...

POWERS Crushes Promised Annualized Savings Rate of $7.5M for Pet Food Partner Fetching $13.8M Only 23 Weeks into the Project

POWERS Improves Processing Capacity, Final-Pass Quality, Packaging Capacity, and Reduces Packaging Waste for Pet Food Industry Leader Project Overview POWERS partnered with a key pet treats manufacturer facing first-pass quality and overall capacity performance issues in their manufacturing process. The...

POWERS Removes Performance Bottlenecks from Major Beverage Manufacturer Facing Unprecedented Demand

POWERS Leads Operations, Maintenance, Planning, and Inventory Control Turnaround at Major Beverage Industry Manufacturer Project Overview POWERS partnered with a major 3rd-party beverage manufacturer facing significant hurdles in meeting a 31% increase in demand forecast for 2021. Operators of two...

POWERS Energizes Dairy and Coffee Beverage Company’s Capacity and Capability While Lowering Costs

Summary A large, private dairy producer in the northeast, which produces dairy products and ready-to-drink coffee beverages, looked to POWERS for ways to increase capacity at reduced costs operationally to remain a leader in their industry. Click here to download...