Proudfoot blog

The latest in operational and digital transformation through people.

   

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 info@proudfoot.com to discuss ways to increase production, reduce costs, and energize your work force.

Tough time finding aerospace technicians?  Get more productive first

Over the last decade, the aviation industry has experienced unprecedented growth, leading to major shifts and changes in the way the market has functioned and will function going forward.  Since the end of the downturn almost a decade ago, Revenue Passenger Kilometers (RPKs), a common measure of airline performance, has averaged year-on-year growth of over 6% (source:  IATA). This growth has been a boon for airlines and is indicative of the overall strength of the global economy.  However, with growth comes challenges.  One of the most pressing of these challenges for airlines, and adjacent maintenance organizations, is the ongoing struggle to meet labor requirements. 

Minimizing the Impact of Trade Tariffs on Your Supply Chain

Every day there is more news about international trade. It can be quite a challenge to make the best decisions for your supply chain without knowing how the environment may change. Not only do you have to consider the potential impact on costs, but also the effects on the performance of your global supply chain. Are you losing sleep over how tariffs might throw a wrench into your cross-border operations? Let’s explore what the impact could be and examine some possible solutions.

6 Considerations for Safer Operations

When companies prioritize safe, healthy operations, they enable their people to bring their best to work.  

Accelerating Growth Video Series: Successful Contractor Management

Last year, Proudfoot worked with five of the top mining construction companies worldwide. Jon Wylie, President of Global Natural Resources at Proudfoot, and Paul Batten, Vice President of Operations, share insight into the processes that lead to successful contractor management – from contract to performance measurement systems to project completion -- on large-scale, complex projects in this brief informative video.

Accelerating Growth Video Series: Length of Engagement

What if you could make significant headway on your most pressing goals, delivering tomorrow’s results, today? With Proudfoot, you can. Jon Wylie, President of Global Natural Resources at Proudfoot, and Paul Batten, Vice President of Operations, discuss the benefits and flexibility of both short- and long-term engagements, including a project that started as a 6-month engagement and expanded to a 2-year engagement, ultimately bringing in over $184 million in annualized benefits for the client. At Proudfoot, we take pride in providing measurable financial benefits to our clients.

Accelerating Growth Video Series: Working With Mining Companies

Proudfoot has a long history of working with top global mining companies on some of the most interesting and challenging developments in the world. We’ve learned a few things in our 73 years of putting our boots on the ground, including how to quickly and thoroughly assess complex operations and provide specific, measurable, actionable solutions. Jon Wylie, President of Global Natural Resources at Proudfoot, and Paul Batten, Vice President of Operations, discuss our work in this brief engaging video.

Accelerating Growth Video Series: Safe Operations

What if you could develop an ambitious new project safely, on time and on budget? With Proudfoot, you can. Jon Wylie, President of Global Natural Resources at Proudfoot, and Paul Batten, Vice President of Operations, discuss the three key priorities that create an aligned, sustainable, safe operations environment.

Accelerating Growth Video Series: Risk, Safety & Productivity

Jon Wylie, President of Global Natural Resources at Proudfoot, and Paul Batten, Vice President of Operations, discuss keeping risk out of projects by having a plan, and working the plan. When safety improves, productivity improves as well. Find out more in this brief, informative video.

Accelerating Growth Video Series: Boots On the Ground

Jon Wylie, President of Global Natural Resources at Proudfoot, and Paul Batten, Vice President of Operations, discuss Proudfoot’s unique “boots on the ground” approach, which allows us to become intimately familiar with our clients’ operations at every level, from the C-suite to the front lines, and how that approach equips us to better serve our clients. Learn more in this brief informative video:

Accelerating Growth Video Series: Integrated Planning Process

Jon Wylie, President of Global Natural Resources at Proudfoot, and Paul Batten, Vice President of Operations, discuss how Proudfoot applies over seven decades of expertise to create innovative, effective solutions for our clients. How did the manufacturing sector inspire a custom product for a mining client? Learn more in this brief informative video:

Accelerating Growth Video Series: Social License & Sustainability

Jon Wylie, President of Global Natural Resources at Proudfoot, and Paul Batten, Vice President of Operations, discuss social license to operate and sustainability in this brief informative video. Are you prepared for the future of mining?

 

Accelerating Growth Video Series: Large Scale Capital Projects

Jon Wylie, President of Global Natural Resources at Proudfoot, and Paul Batten, Vice President of Operations, discuss how to effectively and safely accelerate growth in large scale capital projects. Do you have organization-wide alignment? Are your people leading at all levels? Is your leadership approach instructive? Learn how to effectively accelerate growth in these informative videos.

Active Management, Business Intelligence & the Importance of Front Line Managers

As businesses get smarter and operations more efficient, we’ve seen many companies install a wide variety of business intelligence (BI) tools, all meant to improve systemwide performance management.

It's a great trend, and at many of our clients, these tools and techniques are yielding great results. But as teams adjust to these smarter ways of working, senior management often becomes over-reliant on their tools, leading to a self-perpetuating system that works only for the sake of providing insights to senior managers. Insight is important, of course, but helping the people who turn the wrenches achieve their targeted results is always the ultimate goal.

Interview With Jonathan Robinson, New VP Ops for MRO Americas

Dennis Santare: Good evening everyone, I'm here with Jonathan Robinson, Proudfoot's new V.P. of Operations for MRO. He Joins us with an extensive background in aerospace and defense and in MRO consulting. I wanted to get to Jonathan's thoughts about joining the firm and some of the trends he's seeing out there in the market and what he thinks he could bring to bear for us. We're extremely excited to have him! We've chased him for a long time, and we're beyond excited that he accepted his offer to join us in this MRO journey. Without further ado, Mr. Jonathan Robertson -- hi Jonathan, how are you?

Interview With St. John Cameron, MD Asia, Regarding Aerospace MRO

Dennis Santare (MD, MRO Americas): Hello everyone. I’m talking with St. John Cameron, our MD from Asia who recently, with his team, completed a project for a major aircraft aerospace MRO in Asia. We learned a lot, the client gained a lot, and we wanted to take some time to share that with you. Welcome St John, it's great to have you.

Winning a new client by freeing up 250 man days of hangar capacity?

We enabled a leading aircraft maintenance company to take on 10 percent more work with no extra resources. And no safety or quality compromises.

Interview With Mike Howard, New EVP of MRO Americas

Dennis Santare (MD, US MRO): This is an interview with Michael Howard who is joining Proudfoot as an executive vice president in the MRO practice. Mike, welcome to the firm!