Production Optimization at Horizon Baking Company
Strategic Sprint Package
Initial Challenge:
Horizon Baking Company, a growing wholesale bakery manufacturer with 24 employees and a 5,000 sq. ft. production facility, struggled with their upcoming holiday wholesale demands. After losing two significant accounts the previous season due to delayed orders and inconsistent product quality, they needed to rapidly improve their manufacturing processes to meet growing retailer demands and rebuild trust with key accounts.
Strategic Implementation:
- Complete production line assessment with efficiency bottleneck identification
- Implementation of streamlined batch scheduling system
- Development of real-time quality control checkpoints
- Creation of cross-departmental team coordination protocols
- Design of raw material forecasting and inventory management system
- Optimization of production sequence to minimize equipment changeover time
Measurable Outcomes:
- Increased daily production output by 42% without additional staff
- Reduced manufacturing waste by 35% through process improvements
- Achieved 99.2% on-time delivery rate to wholesale clients (up from 78%)
- Decreased production changeover time by 58%
- Improved product consistency metrics to 96% compliance (up from 83%)
- Recaptured two previously lost accounts and added three new wholesale clients
- Generated 31% more revenue during peak season with lower operating costs