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Manufacturing Case Study

Client Profile

A retail spice manufacturer aims to improve efficiency and reduce conversion costs.


  • Management Operating System (MOS)
  • Training & Development
  • Centerlining
  • Root Cause Analysis
  • Leader Standard Work
  • Visual Management
  • Material Yield Optimization
  • Changeover Cycle Compression


  • High levels of unplanned equipment downtime
  • Supervisors and managers spending extensive days “firefighting”
  • Unclear equipment run-standards, reducing output
  • Poor decision-making due to inadequate metrics and system structure
  • Ineffective problem solving leading to recurrent failures
  • Yield losses due to spillage and overfills


  • Identified meaningful KPIs to prioritize efforts in improving plant profitability.
  • Installed shop floor visual management to promptly address variances at the source of loss.
  • Coached meeting behaviors to drive actions to address poor line performance.
  • Implemented Leader Standard Work for line leads, supervisors, and managers to aid prioritization and establish a consistent cadence.
  • Performed deep cleaning and repairs on problematic line equipment.
  • Established clearly visible “run-right” settings on equipment to optimize product throughput.
  • Created a changeover matrix with significantly reduced target times, applying SMED principles.
  • Developed a process to escalate and resolve the root causes of systemic issues.
  • Installed sustainability audits to maintain progress and foster continuous improvement.


  • Achieved effective and accelerated start-ups and recoveries from downtime events.
  • Reduced plant-wide unplanned downtime, driven by enhanced problem-solving capabilities.
  • 19% reduction in labor cost per case in just four months.
  • 23% improvement in yield loss and ingredient spend.
  • Increased Preventative Maintenance compliance from 40% to 89% through improved working disciplines.
  • Increased line uptime across all production lines.
    • Line 1: ~50% raised to 65%
    • Line 2: ~60% raised to 80%
    • Line 3: ~65% raised to 85%