Case Study: Optimizing Production and Supply Chain Performance in Food Manufacturing
A leading North American food manufacturer sought to strengthen its production, scheduling, and supply chain operations in preparation for future growth.
Challenge:
Despite a strong reputation for quality and customer satisfaction, the company’s performance was constrained by manual data collection, limited automation, and process variability. Warehouse inefficiencies, outdated equipment, and underutilized space further restricted scalability, while cultural silos and reliance on informal “tribal knowledge” hindered cross-functional collaboration.
Approach:
LCG partnered with the client to conduct a comprehensive assessment of their manufacturing, planning, and logistics functions. Using value-stream mapping, statistical analysis, and observation studies, the team identified performance bottlenecks, clarified roles and responsibilities, and developed a phased roadmap for transformation.
The engagement unfolded across three implementation waves:
Phase 1 – Production Optimization: Streamlined setups, changeovers, and run rates; introduced production KPIs such as OEE, yield, waste, and overweight; and improved active supervision and communication routines.
Phase 2 – Planning and Governance: Enhanced demand forecasting and planning accuracy, implemented real-time performance dashboards, and restructured management routines to promote accountability and data-driven decision-making.
Phase 3 – Warehouse and Supply Chain Transformation: Deployed 5S principles, optimized inventory and space utilization, implemented Power BI dashboards, and redesigned procurement and warehouse management processes for greater control and agility.
Results:
The transformation delivered measurable improvements across all key areas of operations:
85% reduction in packaging overweight
22% decrease in dry waste
29% reduction in reprocessed product volume
58% increase in warehouse capacity utilization
Stronger governance routines and real-time visibility through digital dashboards
A continuous improvement culture anchored in accountability and teamwork
Outcome:
By integrating data analytics, structured governance, and cross-functional collaboration, the company achieved step-change performance across production, planning, and supply chain operations. The result: higher efficiency, improved quality, and a more resilient, scalable operation ready for sustained growth.
“The implementation project, organized in sprints and in two main workstreams—warehouse operations and supply chain—was supported by a systemic approach and methodology that we feel confident will help us continue transforming our business. In addition to achieving our strategic objectives, our collaboration with LCG resulted in a projected annual return on investment (ROI) of 1.5 to 1. This partnership was fruitful in achieving our strategic goals, and we would highly recommend their services to other organizations looking to achieve similar results.”
— Chief Executive Officer & Chief Operations Officer, Leading Food Manufacturer
Lessons for Food & Beverage Leaders:
Engage stakeholders early to build alignment and ownership.
Use data and analytics to guide prioritization and sustain improvement.
Phase complex transformations for stability and long-term adoption.
Leverage existing systems and digital tools to enhance visibility and control.
Invest in leadership and communication to embed a culture of accountability.
