Plant Turnaround and Performance
Plant turnarounds led by operators who have run plants.
A plant losing money, or one that should be earning more. We work with food, CPG and industrial manufacturers to find the gap and close it on the floor.
The record
From a $1M monthly loss to profit in six months.
A protein processor's flagship plant: the schedule changing several times a day, lines stopping every minute, daily USDA findings, and one bag in nine given away.
- Measured in the client's own numbers.
What changed at the flagship plant
| Measure | Result |
|---|---|
| Monthly EBITDA | $1.1M swing, from a $1M monthly loss to profit |
| OTIF | About 80%, from the low 40s |
| Throughput | Up 30%, with 17% fewer people |
Led by an operator
Our founder, Assad Mirza, has been turning around plants since 2004, in automotive, industrial and CPG companies, as an employee and as a consultant.
About our founderWhere it hides
The margin you're missing is already in your plant.
It usually hides in changeovers, short stops and giveaway, not in headcount. The first job is to see which losses are worth the most.
- Gaps prioritized, so the plant works on the biggest first.
What's in your gap?
How it works
It's finished when you've verified the targets.
We don't hand over a report and leave. An engagement starts with what the business needs, and it is complete when the targets are achieved and verified by you.
- How long it takes depends on the plant's size, complexity and scope.
From first conversation to verified targets
| Step | What happens |
|---|---|
| Start | Understand what the business needs |
| Assess | A thorough assessment to find and prioritize the gaps |
| Close | Close the gaps on the floor |
| Finish | Targets achieved and verified by you |
When to call
The signs show up before the P&L does.
Most plants in trouble are working hard. These are the signs we look for first.
- If several sound familiar, we should talk.
Is your plant sending these signals?
| The sign | Where it costs you |
|---|---|
| The schedule changes several times a day | Late orders and overtime |
| Lines stop constantly | Lost throughput |
| Giveaway keeps creeping up | Margin, one case at a time |
| Regulators keep writing findings | Late starts and escalations |
Common questions
Something else? Ask an operator
What is a plant turnaround?
Bringing a plant that is losing money or missing its plan back to what the business needs from it, on the floor and in the numbers.
How long does a plant turnaround take?
It depends on the plant's size, complexity and scope. The engagement is complete when the targets are achieved and you have verified them.
How does a plant turnaround start?
With understanding what the business needs. Then a thorough assessment finds the gaps and puts them in priority order.
Is this about cutting people?
The margin usually hides in changeovers, short stops and giveaway, not in headcount. A plant that runs better needs fewer hours: at that flagship plant, throughput rose 30% with 17% fewer people.
Do you only work in food plants?
No. We work with food and beverage, CPG and industrial manufacturers, and the investors who own them. Our founder has been turning around plants in automotive, industrial and CPG companies since 2004.
What if the plant manager seat is open?
We can have an interim operator on the ground in 72 hours. See Interim Leadership
Everyone on the job has done the job
Where is your plant's gap?
Talk to an operator who has run a plant like yours. We reply within one business day.