Facing aggressive annual growth and significant operational and cultural performance challenges, POWERS facilitates rapid and sustainable improvements for snack food industry pioneer.
Our client is one of the nation’s premier nut and trail mix snack manufacturers. The company is a pioneer in the industry and strives for responsible, transparent, and sustainable practices throughout its extensive global supply chain. Their responsibly sourced materials from thousands of farmers worldwide contribute significantly to local farming economies.
When partnering with POWERS, their primary operational performance goal was to increase production capacity on two key production lines to satisfy customer demand for the mix of products produced on these special lines. In addition, to keep pace with 14% annual sales growth, production capacity and inventory positions were required to increase continually.
Plant Management was struggling with a shorthanded and undertrained workforce, filling in a substantial number of positions with temporary labor and covering for open supervisor positions by expanding the work scope of other supervisors and lead hand roles.
To meet customer demand, the plant was being run six
to seven days a week with the same crewing, an unsustainable plan resulting in elevated levels of employee call-offs.
On-Time-in-Full (OTIF) delivery suffered because of limited capacity, limited ingredient supply, and labor constraints. For these same reasons, there was no fixed schedule in place. Instead, schedules were constantly being changed based on available ingredients and operators.
Many MOS (Management Operating System) meetings had been eliminated due to concerns about the spread of the COVID-19 virus. e.g., shift handover meetings.
Significant production line mix variations make it challenging to develop meaningful production line trend data and establish daily/weekly production targets.
Plant Management was convinced that the only way to increase plant capacity and throughput was by increasing headcount and staffing up key supervisory roles.