Our client faced the cumulative effects of massive customer demand combined with the lingering impact of pandemic labor challenges and turned to our team to rapidly improve productivity.
Our client is a large-scale poultry processor for one of the largest mass-market retailers in the world. Their recently completed, state-of-the-art facility was brought on line to serve the retailer’s commitment to providing only the highest quality products for its customers.
Despite its relatively short tenure in business, this facility has grown to be one of the region’s largest poultry producers and a welcome boon to the surrounding community.
This poultry processing powerhouse struggled with the combined challenges of being one of a few chicken processing plants in their region with the added chaos of being hard hit by the pandemic.
Though the top leadership had years of chicken processing experience, they had to draw on local talent unfamiliar with the challenges of running a chicken plant to run its day-to-day operation.
The young team assembled was brought on board during the pandemic and had grown accustomed to managing by survival, given their extreme resource challenges. It was time to teach the team how to manage.
Hitting planned case counts was the main objective of the management team. Yield and labor waste were not daily metrics they used to drive the business and, in some cases, had become so commonplace that management could not even see them.
In an extreme example, whole birds littered the floor around the Deli Line. Critical performance metrics, including yield data, were not incorporated and visible on the production floor.