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How a major food producer transformed a struggling plant and boosted worker morale

When a major food producer acquired a new production facility to keep up with growing demand, the plant faced challenges in nearly every phase of operations. Throughput and quality were suffering, costs were increasing, and the work force was frustrated. With the help of Proudfoot, they rapidly transformed their wall-to-wall operations and engaged the enthusiasm of their people.

Prior to engaging Proudfoot, their new Ohio packaged foods plant was struggling with numerous challenges related to packing, sealing, and cooking. Inefficient changeovers and sanitation procedures were also leading to excessive machine downtime.

Lack of effective communication and management visibility were major factors. “One of the issues we had was communication from the supervisor on the floor.” said their President. There was also no accountability for performance on the lines. “It didn't matter whether you ran good or ran bad,” said a Production Line Lead. 

The organization was determined to quickly reduce costs and increase throughput in order to capitalize on the fast approaching holiday season. With no time to lose, the Proudfoot team got to work investigating the root causes of problems and addressing them at the source.

A key to the success of the project was how Proudfoot built trust with their people at every level from the beginning. “I am very proud of the entire plant embracing this project,” said their VP of Food Safety. This level of participation and trust allowed us to uncover improvement opportunities that leadership would otherwise never have known about.

In a short period of time, we helped the company improve systems, tools, and processes throughout their operation. Establishing our #HeadsUP active management leadership model increased employee engagement, contributing to:

  • 16% reduction in cost per 100 lbs.    
  • Exceeded production targets by 7.5M lbs.
  • 40% increase in OEE
  • 20% reduction in machine downtime
  • Changeover time reduced 19 hours per week
  • Year 1 savings: $6.3 million

“The level of engagement has gone up greatly… I think this not only helped us improve our operations and financials, but also the morale of our associates,” remarked the Senior Director of Finance.

Our end-to-end transformation of their operations and company culture propelled them to record production volumes and positioned them for ongoing success.

Download the full Case Study to learn more about how Proudfoot engaged their people to break through performance barriers and lift work force morale.

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Contact the Proudfoot Industrials Management Team today at 404 260 0600 or to discuss ways to increase production, reduce costs, and energize your work force.