Business Turnaround: Frozen Food Processor, WA

The Problem: A food processor was facing a bank action due to their inability to service a $20M loan. They struggled with managing operations, customer order fluctuations and inventory in multiple locations leading to 6 months of no profit. We were given 8 weeks to save this 3rd generation family-owned company.
The Strategic Pivot: The Company engaged us, and we developed a plan.
Best Practice #1: Convert C-Suite Financial Goals into Actionable Shop Floor Metrics. Align with the CFO, develop and implement KPI’s on the floor to support the company’s financial needs.
Best Practice #2: No Plan Survives First Contact – Prioritize Real-Time Execution Over Theoretical Strategy. With 8 weeks to return the business to profitability, quickly identify and implement changes across 3 facilities performing small kaizens with Team Members.
Best Practice #3: Lead Time is the Ultimate Metric – The Hidden Driver of Profitability Base production on actual customer orders, reduce equipment downtime, work in process inventory and labor. Together, we created a clear execution plan to implement these strategies systematically.
Best Practice #4: Standardize to Sustain Standardized Work developed to lock in changes. Leaders were trained to develop and manage Standardized Work.
The Outcome:
  • Business returned to profitability in 6 weeks.
  • Lead Time reduced by 46%.
  • Overtime reduced by 90%.
  • Saved a third-generation family business.