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Representative illustration: A newly acquired North American dessert maker needed more throughput and productivity, with lower overhead.

Case Study · Food & Beverage

A newly acquired North American dessert maker needed more throughput and productivity, with lower overhead.

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1Challenge

Ovens ran only 15 of 24 hours, starved by slow crumbing and panning. Maintenance was reactive with no weekend PM, and nonstandard cups wasted crust and batter.

2Approach

  • Drove adherence to line metrics and SKU-based bake standards, reaching 2,000 pans per hour
  • Reformed maintenance with an attendance policy, work orders and a critical equipment list
  • Standardized crumb cups and leveling tools for consistent crusts and less waste

3Results

20%

Throughput increase ($49M to $58M annualized)

25%

Productivity improvement (estimated)

>$2M

Reduction in annualized labor expense

Spare parts inventory tripled to $180K, enabling weekend preventive maintenance.

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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.