Golden Boy Foods - productivity improvement

Productivity Improvement – click on the project breakdown diagram below for a detailed analysis

Objectives
Through our detailed planning, we determined the following key milestones:

• Confirm schedule, budget, and savings targets by week 10
• Dispatch all finished goods from consolidated location by week 19
• Manufacture all non-nut products from consolidated location by week 23
• Manufacture all nut products from consolidated location by week 32

Approach and results:
The Grant Thornton Productivity Improvement team made improvements to confirm schedules, budget and savings by: 

• Establishing a steering committee comprised of eight client-led teams and assign objectives/targets
• Finalizing demolition and construction details, equipment layouts, and warehouse layouts
• Negotiating and finalizing all contracts for work performed by trades and subtrades
• Confirming ability to obtain permits from city council

Improvements were made in order to dispatch all finished goods from a consolidated location by:

• Negotiating a new fleet of lift trucks operable in a Very Narrow Aisle (VNA) application
• Completing implementation of Warehouse Management System
• Disassembling and re-erecting racking to VNA specifications
• Installing new docking equipment and loading safety devices

Manufacturing all non-nut products from a consolidated location was achieved by:

• Removing and relocating 10 packaging machines
• Modifying drainage, HVAC, and utility feeds for equipment
• Installing hand wash stations and necessary allergen controls to meet food safety standards
• Ensuring smooth employee transitions with new lunchroom and bathroom facilities

Manufacturing all nut products from consolidated location was achieved by: 

• Removing and relocating three fryers with supporting infrastructure and two oil storage tanks
• Removing and relocating six packaging machines
• Designing and installing a new waste water handling system
• Installing a chiller unit for nut raw material cooling