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Representative illustration: A family-run dehydrated potato processor had a solid MOS, but reporting and accountability gaps were eroding margins.

Case Study · Food & Beverage

A family-run dehydrated potato processor had a solid MOS, but reporting and accountability gaps were eroding margins.

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1Challenge

Overfilled packages and untracked losses cost an estimated $20M a year across four plants, crews did not follow SOPs, and no optimal throughput target existed.

2Approach

  • Upgraded the yield MOS and added SPC charting to cut overage waste
  • Strengthened PDCA cycles, work-to-time relationships, capacity planning and shift playbooks
  • Set a throughput target from the top 10 run rates for high-performing SKUs

3Results

$2.4M

Projected annualized savings from crewing

$1.2M

Projected annualized savings from yield and throughput

$3.6M

Expected total savings

OEE reporting now ties directly into the MOS and daily and weekly reviews.

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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.