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Up to 20% more capacity, in six days instead of seven
Keystone Foods
Food & Beverage
+20%
production capacity, with more days off
104 to 141
days off per year
+24
line hours, no new capital
The problem
Demand pushed this Alabama chicken plant from Monday to Friday to 7 days a week on forced weekend overtime, and the short-term fix became the norm. The plant shut down only 33 days in a year. Employees were exhausted, which threatened morale, safety, and productivity, and demand kept growing with no capacity left in the schedule.
What we did
- Reimagined the whole operation, from raw material supply and sanitation to equipment and distribution
- Facilitated planning between plant management and corporate production schedulers
- Enabled up to 42 hours of continuous running between sanitation cycles
- Identified training gaps and placed people with the right skills for coverage
- Designed schedules with built-in and volunteer overtime for those who want it
The results
- Up to 20% more production capacity
- 104 to 141 days off per year for employees
- 6 days to do what used to take 7, plus 18 to 24 hours of capacity for growth
- 24 additional line hours with no new capital equipment
- Lower turnover and positive employee feedback
We implemented a system that gives everyone what they want, overtime to the people who really want it and more time off for those who don't. Everyone gets more time off and has the ability to spend more time with family.
Stuck on forced weekend overtime? Get a 30-minute workforce diagnostic.
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