When I joined CIFT, one of the things that excited me most was the chance to share what I’ve learned over a number of years in manufacturing with a broader audience. I’ve seen firsthand how manufacturers face mounting pressures to stay competitive. Rising costs, supply chain challenges, and maintaining quality while keeping margins healthy—these are issues we all wrestle with.
At CIFT, we are launching manufacturing site evaluations to uncover practical opportunities for improving efficiency and reducing waste. A recent assessment we completed illustrates just how transformative a targeted, data-driven evaluation can be.
What Is a Manufacturing Site Evaluation?
When we conduct a site evaluation, our goal is to benchmark a facility’s performance against industry standards while digging into critical areas like material efficiency, equipment reliability, and workforce utilization. We’re not just looking for problems; we’re searching for solutions—ways to cut costs, improve throughput, and ensure the operation runs smoothly.
For all manufacturers, raw materials are one of the largest expenses, so reducing waste and optimizing material usage is often a major focus. But cost isn’t just about materials. Downtime and bottlenecks in production can choke profitability. By analyzing labor utilization, for instance, we can identify where staffing adjustments or automation could improve productivity. A stable, well-trained workforce also plays a key role in maintaining consistent output and quality.
Another critical area is equipment reliability. Frequent breakdowns aren’t just frustrating—they’re costly. Improving maintenance practices and ensuring equipment runs reliably are essential to keeping production on track. Alongside this, evaluating operational management and safety protocols ensures the entire process stays efficient and compliant with regulations.
Finally, we incorporate lean manufacturing principles and environmental considerations. With sustainability becoming a growing priority, reducing waste and adopting eco-friendly practices can benefit both the bottom line and the planet.
This structured approach helps us zero in on inefficiencies and create actionable roadmaps for improvement. A recent evaluation for a confectionery manufacturer demonstrates the real-world impact of this process.
Case Study: Tackling Hidden Potential
One of our clients, a confectionery company, faced a frustrating and costly problem that was felt to be inherent with their chocolate dipping operation. A flaw in the production line design caused chocolate to accumulate and separate from the product, leading to significant waste and contamination. This not only hurt their bottom line but also required extra cleaning and maintenance efforts.
Our evaluation identified and quantified the losses, and the numbers were staggering. They were losing thousands of dollars each year due to wasted chocolate. But identifying the problem was just the beginning.
We recommended modifications to the equipment design to reduce material loss and contamination. We also proposed enhancements to the supply line to maintain product consistency and updated safety protocols to minimize manual handling. On the maintenance front, we outlined steps to ensure equipment ran reliably, reducing downtime and extending its lifespan.
These targeted recommendations weren’t just about fixing immediate issues. They were designed to build a more efficient, cost-effective, and sustainable operation for the future.
Expected Outcomes
The projected results from implementing our recommendations are compelling. The company expects a significant reduction in material waste, improved product quality, and more efficient cleaning processes. Even more importantly, they stand to recover a large portion of their annual losses, boosting profitability while achieving more sustainable operations.
A Broader Perspective
This case study is a reminder of how critical it is to step back and assess the bigger picture. For any manufacturer—especially mid-sized ones—site evaluations are a powerful tool. They uncover areas where you’re bleeding resources, highlight opportunities for improvement, and provide a clear path forward.
Having worked in the food industry for two decades, I know how hard it can be to step away from the daily grind and take a hard look at your operation. But as this project shows, taking the time to assess and optimize can pay off in ways that go far beyond the balance sheet.
If your company is grappling with rising costs, inefficiencies, or quality challenges, a manufacturing site evaluation might be exactly what you need to turn things around. Let’s work together to streamline your processes, reduce waste, and position your operation for long-term success.
