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 bottling and canning plants, our new client/partner faced a sharp decrease in capacity utilization of nearly 40% due to excessive unplanned downtime, labor shortages during the pandemic, and challenges introducing and growing new product lines.

While demand was headed skyward, their ability to meet that demand was flagging or bottoming out at historic lows. Although the company had a robust stated culture, it was not aligned to performance expectations and outcomes.

Our analysis uncovered significant challenges in operations, maintenance, planning, and inventory control, but two areas of opportunity stood out: front-line leadership training and supply chain management.

A historical lack of training and development programs designed to meet flexible production and product demand left their front-line supervisors and managers ill-equipped to manage the extreme, pandemic-induced demand fluctuations. Additionally, poorly executed supply chain planning and controls led to daily raw material and packaging shortages.

Production Improvements

  • 7% YOY gain in overall plant equivalent cases
  • 30% improvement in Clean in Place (CIP) times
  • 30% reduction in startup delays

Maintenance Improvements

  • 120% increase in maintenance work order execution to schedule
  • 30% increase in mechanic utilization
  • 39% reduction in mechanic overtime percentage

Logistics Improvements

  • 44% improvement in inventory accuracy
  • 100% pass rate of internal inventory audits
  • 80% reduction in refrigerated truck wait times

Click here to download a PDF copy of this article

Save it to read later, or share with a colleague

Read More Case Studies

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...

POWERS Sparks $4M Turnaround For Cold Storage Distribution Center, Transforms Management Operating Systems

Summary One of the world's largest independent poultry producers needed POWERS to help significantly upgrade front-line management skills, behaviors, processes, and controls to improve operational performance and the bottom line. POWERS identified the business's true capabilities, changed expectations, and implemented...

A Tale of Three Supply Tiers: POWERS Helps International Automaker Fix Supply Chain Woes and Boost Productivity

International Automaker A multi-billion-dollar powerhouse automaker approached POWERS for help with their assembly facilities in the U.S. With a presence on every continent except Antarctica, this company relied on punctual, high-quality delivery from its Tier 1 and Tier 2 suppliers....

POWERS Helps Agricultural Giant Rein in HR Issues Caused by Rapid Growth

Private Agribusiness Producer / Supplier A large, privately owned global agribusiness corporation with over 8,500 employees asked POWERS to help deal with some challenges caused by their rapid expansion. Founded in 1946, the company had successfully grown into one of...

Midwestern Turkey Producer Gets Major Maintenance Upgrade From POWERS

International Turkey Producer This Midwestern turkey producer was founded by 15 growers in 1998 and now packs for over 60 local and national brands which are distributed internationally to supermarkets and restaurants. They were challenged with equipment and line unreliability...

POWERS provides expertise for new facility built by major food producer

Major Food Producer A major poultry producer secured an additional product supply contract and started construction of a new facility in early 2019 with planned ramp up/start up in January 2020. Besides the complexities and coordination challenges with new construction,...