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Representative illustration: A vertically integrated pork producer needed better yield, productivity and profit at its main plant.

Case Study · Food & Beverage

A vertically integrated pork producer needed better yield, productivity and profit at its main plant.

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1Challenge

700+ hours of observation found MOS gaps, manual scheduling, slow shift starts, unmeasured rework and run-to-failure maintenance.

2Approach

  • Employee Involvement Prototype to remove waste in live operations
  • Optimum run parameters, standard work and faster start-up
  • Upgraded KPIs, floor coaching and post-project audits

3Results

~$16M

Annualized benefit

700+

Hours of observation

3

Further initiatives

Impact: yield ~45–48%, labor ~35–40%, overtime ~10–15%.

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© USC Consulting Group 2026 | Food & Beverage. Representative industry image. Results are engagement-specific; sizing and forecast figures are labeled as such.