A distinguished player in the food manufacturing industry embarked on a transformative journey to implement and sustain a Management Operating System (MOS) centered around its automated bakery system. The primary objectives were to supply pie shells to their current facility and reduce purchasing costs. However, the company faced multifaceted challenges, including low production throughput, high employee turnover, and a prevailing culture of complacency with the existing operational status quo. This case study unveils the comprehensive efforts undertaken by a prominent food manufacturer in collaboration with POWERS to address these challenges and achieve significant operational enhancements.
The central focus of this food manufacturer’s endeavor was to enhance the performance of its automated bakery system, responsible for producing pie shells for their current facility as well as external customers. The client identified two primary objectives: to ensure a consistent supply of pie shells and to reduce purchasing costs. In their pursuit of operational excellence, the food manufacturer confronted several pressing challenges:
1. Low Throughput: The client’s cook room struggled with a subpar production output, resulting in a daily batch production volume that fell short of optimal levels.
2. High Employee Turnover: The company grappled with a significant issue of employee turnover, impacting not only workforce stability but also incurring substantial training costs.