Case study · Food & Beverage
Pork producer gains $16M in annualized benefits from yield, labor and overtime
A vertically integrated pork producer wanted better yield and productivity. After more than 700 hours of observation, USC used employee-involvement prototyping in live operations to remove waste, set run standards and speed shift start-ups.
Results
$16M
in annualized benefits
The producer launched three further initiatives with USC.
The situation
Yield and productivity across the pork producer's operations were below where the company wanted them, and overtime was adding cost.
What the assessment found
- Gaps in the management operating system
- Manual scheduling and slow shift starts
- Unmeasured rework
- Maintenance run to failure
How the work was done
Waste: prototype in live operations
Used USC's Employee Involvement Prototype, a shift-by-shift trial of changes with the crews who do the work, to remove waste while the plant kept running.
Standards: run at the optimum
Set optimum run parameters and standard work, and sped up start-ups.
Management: coach and audit
Upgraded key performance indicators, coached on the floor and ran post-project audits.
$16M
in annualized benefits
Lasting impact
The producer realized $16 million in annualized benefits and went on to three further initiatives with USC.
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