Project Overview
The Challenge
A major manufacturer in the renewable energy sector was facing escalating labor costs, frequent production delays, and frontline teams that couldn’t consistently hit targets. Despite long hours and good intentions, the output wasn’t where it needed to be. Overtime was out of control, schedules were slipping, and communication between shifts was unreliable.
The root issue wasn’t a lack of effort, it was a lack of structure. Expectations were unclear. Supervisors managed differently across shifts. Production plans changed without notice, and floor teams were often left guessing what needed to happen next. Without a consistent process to manage work, every day felt like starting over.
Leadership recognized the symptoms: late orders, labor overruns, and high frustration across departments. But without visibility into the day-to-day breakdowns, it was hard to chart a path forward. They needed help connecting the dots and turning reactive management into proactive performance.
Performance Results
Read the Full Case Study Here
The Engagement
POWERS partnered with the manufacturer to get a ground-level view of how the operation was really running. Our team spent time on the floor, not just in meetings, observing workflows, analyzing shift transitions, and sitting in on team huddles. We didn’t assume, we verified….
What we found was a set of hardworking teams operating without a shared playbook. Production expectations shifted daily. Supervisors were often unsure how to prioritize tasks. There were no simple systems in place to check progress mid-shift or adjust before problems escalated.
Our job wasn’t to add complexity, it was to bring clarity. We worked directly with plant managers, team leads, and frontline supervisors to build a practical structure for day-to-day execution. One that everyone could follow, and that would hold up under real manufacturing pressure.
The Fix
Together, we focused on three key areas that had the biggest impact on performance:
1. Leadership Consistency
Supervisors needed more than motivation, they needed a clear, repeatable way to lead. We worked with them to define and model the core behaviors that drive results: setting daily expectations, coaching in the moment, and reinforcing accountability without micromanaging. This helped align leadership styles across shifts and made sure the same standards were being upheld plant-wide.
2. Scheduling Discipline
Production schedules were often built around “what’s left to do” rather than “what should be done first.” We introduced a simple planning process that helped frontline leaders allocate labor more effectively, based on actual demand and process bottlenecks. With more disciplined scheduling, teams could focus energy on what mattered most, and stop burning time and hours chasing yesterday’s problems.
3. Clear Daily Targets
Without performance visibility, it’s impossible to manage effectively. We implemented visual tools and simple metrics that gave supervisors and team members a live view of how they were tracking each shift. This made course corrections faster, boosted communication, and created shared ownership of outcomes.
The Results
The transformation wasn’t theoretical, it showed up in real dollars and hours saved:
- 💰 $1.2 million in added profit from improved output, reduced labor costs, and better use of available time.
- ⏱ 50% reduction in overtime, thanks to smarter scheduling and better shift execution.
- 📈 Stronger throughput, fewer delays, and more predictable performance across all production lines.
Supervisors reported less chaos and more control. Teams hit their goals more consistently. Leaders gained confidence that each shift was building on the one before it, instead of cleaning up after it.
What Leadership Had to Say
“Before POWERS, we were managing by firefight. Everyone meant well, but we were always behind. Now, we have structure. Our leaders are more proactive, and our teams are more consistent. You can feel the difference walking the floor.”
How POWERS Can Help
POWERS works shoulder-to-shoulder with manufacturing teams to eliminate waste, reduce labor pressure, and build high-performing frontline habits that last. We don’t rely on theory. We bring practical, proven tools and leadership strategies that help operations run with more clarity, focus, and accountability.
If you’re tired of chasing the same problems week after week, and ready to see results like these in your facility, let’s talk.
Contact POWERS today to learn how we help teams drive performance from the floor up.
