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Click to enlarge
Excess Plant Capacity Utilization
Challenge: Create incremental volume utilizing excess capacity at a breakfast sausage factory.
Actions: Adapted a production line to produce bun-size Bratwurst, Polish, and Italian Sausage versions of the pre-cooked, frozen breakfast Sausage—ready in just :60 seconds for "instant" lunches or dinners.
Results: Estimated ramp-up to an incremental 3 million pounds per year, with contribution margin of $1.3 million. Slightly exceeded year one goal of 66% of projected ongoing sales in the rollout year.