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Case Study

International Food Manufacturer

West Coast-based producer of pastas, prepared sauces and meals for distribution to major grocery chains across the United States. Owned by foreign-based multi-national food company.

Revenue

$1 billion U.S.-based sales

Industry

Food & Agribusiness, Manufacturing

Services Provided

Enterprise Performance Improvement

Situation

Underperforming consolidation of several acquisitions resulting in low yields from processed foods and excessive labor costs to produce products, and higher than normal costs for distribution transportation and freight costs.

Accomplishments

  • Enterprise process improvement engagement focused on the redesign of process manufacturing workflows utilizing LEAN manufacturing techniques, improving production yields from low 70% to 95% plus.
  • Production planning redesign to reduce overtime and labor costs through improved workflows and scheduling.
  • Renegotiated contracts for temporary labor, product packaging and shipping freight costs.
  • Redesigned product movement protocols to support and reduce costs related to nationwide shipping.