The challenge
When profitability and KPI performance started dipping at Cargill’s Eddyville plant, management instituted an Accelerate program to stop further deterioration.
As a leading purchaser and processor, Cargill is committed to sourcing sustainably produced corn in major supply chains worldwide. Part of this commitment is to work on continuous improvement in areas that are relevant for the farmer, customer and the environment.
While the Eddyville plant already had several improvement projects in place, there were too many competing priorities, no project sponsors, and project leaders who didn’t fully understand their roles. In addition, there was a lack of support for these projects. So, when performance at the Eddyville plant started faltering, plant management had to act quickly. They were looking for a structured process to improve accountability, project execution, KPIs, and shop floor involvement.
Industry
Food
Cargill Inc., one of the world’s largest agribusiness corporations, is a privately held business with diverse product lines and processes from steel production to grain milling to commodities trading. With more than 150 years of experience, Cargill currently employs 160,000 people in 70 countries.
The solution
- Rapid best practice deployment
A daily management system and Implementation Task Forces (ITFs) were implemented to embed Visual Management, 5S, Teamwork, and Focused Improvement best practices. - Project review and governance
The next step was to reduce the overall number of legacy projects and training the project leaders in the use of the project notebook in TRACC. Project sponsors also received thorough training in project governance. - Build capability and embed best practice
The primary focus areas of the Rapid Best Practice Deployment program included operational performance, behaviors and mindsets, and manufacturing practices. The TRACC foundation best practices (Teamwork, 5S, Focused Improvement, and Visual Management) were implemented to focus on frontline capability building, while operational performance was addressed via profit improvement projects (PIPs) and regular control loops. - An improvement system that sustains the gains
With TRACC as the backbone, a fully integrated improvement system was developed and owned by all employees. Not only did this ensure sustained results, but the team’s efforts gained recognition across the broader group.
The results
Accelerating from bottom to top divisional performance standings
Within six months, the Eddyville plant was more efficient and more productive with improved interdepartmental teamwork, workforce empowerment and better adherence to the DMAIC process.
US$700,000+ realized in project savings
Moved from bottom of divisional performance standings to nearing the top within six months
On track to achieve 150% of their normal target
Active projects currently valued at more than US$7 million in potential savings
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