A large food-processing conglomerate

Background

This project was with the Specialty Snacks Group covering three manufacturing sites that produced meat snacks and corn type products for famous brand names.

The Problem

Corporate had a master plan to remove $18 million dollars from these businesses in a span of three years. Their management was unable to attack all of the business problems in this short period of time.

Scope and Assignment

Synergetics was asked to take a lead role and work collectively with an internal team to reduce operating costs on all fronts including salary, direct & indirect labor, yields, productivity and overtime expense. We dissected all parts of the business; evaluated work standards, yield specs & yield lost points, work flows & work methods, sanitation, quality & lab test requirements, multiple paper & off line reporting systems to sort out non value added costs.

The Results

A streamlined salary reorganization. A reduction from four reporting systems to a single automated one. Improved productivity that reduced the need for 1 million dollars in weekend overtime. A yield improvement of 2.4 million dollars by smokehouse control and reduced floor waste and product overfill. A direct and indirect labor reduction of more than 2.6 million dollars and a return of previously outsourced product back into the facility at a much cheaper cost.

In conclusion the goal of 18 million dollars will be achieved in under two years versus the original three year plan.

Synergetics Installations Worldwide, Inc.

75 Congress Street, Suite 201 • Franklin Block Building • Portsmouth, New Hampshire 03801 • (603) 433-8940