Background
A leading global consumer goods company with over 100 well-known brands was unable to meet the dramatic increase in COVID driven demand in their canning jar division. Their facility was already running 24/7 on all automated case packing equipment and lead time on new machines was over a year. Due to a previous working relationship with XPress360, this client contacted us looking for help to meet the new demand. They knew we had the people and equipment required for the job, but they were unsure we had the immediate capacity needed to help them take advantage of the new sales demands for their 12-count cases and Lids/Bans.
Challenges
- To understand all the specifications and requirements of the customer.
- Reconfigure facility to handle the processing up to 250,000+ Jars per day.
- Staff up and Train 100+ employees over 2 shifts dedicated to this new volume of work.
- Add additional equipment to make sure we could operate 2 shifts daily without stoppage.
- Timeline- 30 to 60 days to get everything in place.
- Managing communication and planning of all products needed each day.
- To effectively handle scheduling for shipping/receiving to prevent overcrowding space.
Solutions Approach
- XPress360 met with customer's Planning, Production, and Logistics Teams to fully understand all expectations and challenges.
- Set up a new office support team dedicated to these new lines of business.
- Committed 40,000 square foot and 11 docks to handle the workloads.
- Worked with our Staffing Company (TSI) to hire and train 100+ employees over 2 shifts.
- Included new quality/incentive- based pay to reward the most productive employees.
- XPress360 offered volume discounts to Client to help lower their costs.
Results
Week 1- Daily Volume started at 5,000 12-pack cases (60,000 jars) and 10,000 12-pack boxes of lids/bans. At the peak of summer volume was up to 25,000 cases (300,000 Jars) and 60,000 boxes of lids/bans.
Customer was able to increase their sales by over 50% and received volume discounts from XPress360 at the same time!
