Organizational Alignment and Step-Change in Performance with LCEsmartr
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Introduction
One of the largest farming and food manufacturers in the United States, prowith a dedicated workforce of 2,500 employees across multiple sites had a goal to enhance asset reliability and improve overall productivity.
Background
The company aimed to:
- Identify opportunities to reduce asset downtime and improve reliability
- Increase throughput and asset availability to meet customer demand
- Maintain best-in-class food and employee safety standards
- Develop a strong management team with enhanced leadership skills
- Position themselves as the preferred employer in the area to reduce turnover and attract top talent
Solution
To achieve these objectives, US Sugar partnered with Life Cycle Engineering (LCE) consultants to implement Reliability Excellence using LCE’s proprietary online platform – the LCEsmartr Playbook. Key initiatives included:
- Using LCEsmartr’s eLearning programs for capability building and onboarding: With 54 users, the company completed 71 courses22 in progress, demonstrating significant engagement and investment in training.
- Implementing standard work: using the standard work packages included in LCEsmartr Playbook promoted consistent maintenance practices across multiple sites and facilitated shared lessons learned.
- Utilizing program management reports: managers used eLearning progress reports and engagement metrics to make program decisions.
Impact
Using LCE’s Reliability Excellence consulting services and leveraging the LCEsmartr platform for standard work and online training across multiple sites accelerated the company’s journey and encouraged long-lasting program sustainability. By focusing on improving performance gaps in the areas of reliability engineering, storeroom management, and work management, the company anticipated results such as:
- A 3-year ROI from the program of >6:1Operational efficiency improvements from increased capacity/production rates and decreased scrap of $5M
Total savings of $6.8M The online training evaluations from participants were overwhelmingly positive:
- 89% reported confidence in applying what they learned
- 84% found the action plans helpful
- 95% valued the eLearning resources provided
For an investment of approximately $1,000 per user, this company received value of 5x that per user – received $322K in value. In addition, the company uses eLearning in LCEsmartr as a program sustainment tool, providing useful onboarding and contributing to improved employee engagement and a more resilient culture.
Conclusion
Through strategic partnerships with LCE reliability consultants and the adoption of eLearning and reliability best practices through the LCEsmartr Playbook, the company transformed its operations, resulting in a more engaged workforce and improved asset management . The initiative not only enhanced performance but also solidified the company’s position as a preferred employer in the region.
Quick Summary
A large U.S.-based farming and food manufacturer collaborated with LCE’s Reliability Excellence consultants and utilized the LCEsmartr Playbook to:
- Achieve over $322K in eLearning value
- Increase employee engagement and enhance leadership skills
- Increased capacity, production efficiency, and maintenance cost savings estimated nearly $7M
- Grow the program and sustain program improvements for over 3 years…and counting!
Unlock your organization’s potential with expert training and resources from Life Cycle Engineering. For more information, email us at info@LCE.com or visit LCEsmartr.com.
