Case Study|Food & Beverage

A global meat processing leader lifted on-time startups 75%, from a 52% to a 91% average, by getting supervisors back to leading and aligning culture with performance, not adding capacity but ending the firefighting.

Global Meat Processing Industry Leader
Results at a Glance
52% to 91%
On-Time Startups
8%
Pounds Per Labor Hour
17%
Overtime Reduction
Executive Brief

Demand was soaring and commodity prices were climbing, but performance was flagging and the operation ran on continuous day-to-day firefighting. Supervisors had drifted off their core job, spending only 15% of their time coaching and directing while losing 32% of the day to frontline employee work, and the Management Operating System had deficiencies across the organization. POWERS built a more robust and definitive Management Operating System, trained managers and supervisors hands-on, clarified roles and responsibilities, and worked to align the company's values and purpose with daily behaviors. On-time startups improved 75%, from a 52% to a 91% average, pounds per labor hour rose 8%, and overtime fell 17%, while frontline leaders gained the clarity and confidence to lead.

Frontline Leadership · MOS
The Situation

A dependable, always-innovating partner was running on continuous firefighting, from the top floor to the shop floor, with no relief in sight.

This industry-leading global meat processor had built its reputation as a dependable partner, committed to continuously improving its products and services and promising quality, on-time delivery, superior customer service, and real value. But demand was ever-soaring and commodity prices were rising, and persistent supply challenges across the food sector forced the company to redouble its efforts simply to stay competitive and exceed partner expectations in difficult market conditions.

Underneath the external pressure sat a deeper structural problem. The culture ran on continuous day-to-day firefighting with no relief, a pattern that reached from the top floor to the shop floor. The clearest symptom showed up in how supervisors spent their time: only 15% went to actual supervisory work, coaching, guiding, directing, and engaging their direct reports, while 32% of the day was consumed performing frontline employee work instead of leading. The Management Operating System had deficiencies across the organization, roles and responsibilities were not clearly defined, and frontline leadership training was insufficient for the demands of the job.

The consequences landed where they mattered most. Plants were underperforming in capacity, yield, and overall productivity, labor costs were climbing on overtime, and margins were tightening against projected commodity price increases. What leadership needed was not a one-time fix but a system: a way to reverse the chaotic environment, give supervisors back their real job, and align the company’s stated values with how people actually behaved every day.

The Diagnosis

Six structural gaps producing the same outcome from six directions.

Supervisors who had stopped supervising

Only 15% of supervisors' time went to coaching, guiding, and directing their direct reports, while 32% of the day was spent doing frontline employee work. Leadership effort was being absorbed by tasks that were never supervisory.

A Management Operating System with deficiencies

The Management Operating System had gaps across the organization. Without a robust, definitive system, daily execution had no reliable structure to run on.

Roles and responsibilities left undefined

Responsibilities were not clearly defined, for supervisors or across the production process. When ownership is unclear, work falls through the cracks and accountability dissolves.

Frontline leadership training that fell short

Frontline leadership training was insufficient for the demands of the job. Leaders were being asked to steady a chaotic operation without the skills and behaviors to do it.

Plants underperforming as overtime climbed

Plants were underperforming in capacity, yield, and overall productivity, and labor costs were rising on overtime. The operation was paying more to produce less.

A culture running on firefighting

The culture was built on continuous day-to-day firefighting with no relief, just as tightening commodity prices squeezed margins. Reacting to the latest crisis left no room for planning or improvement.

What POWERS Did

Got supervisors back to leading and aligned the company's values with daily behavior.

POWERS treated the engagement as a leadership and culture challenge, not a one-time productivity push. The work started by building a more robust and definitive Management Operating System, giving the organization the structure its daily execution had been missing. With that foundation in place, managers and supervisors received hands-on training and guidance, learning the specific skills and behaviors needed to reverse the chaotic, firefighting environment they had been living in.

In parallel, POWERS clarified the roles and responsibilities of supervisors and of the entire production process, so ownership was clear and effort stopped falling through the cracks. As the structure took hold, frontline leaders were freed to focus on what supervisors are actually for: resolving problems and planning labor and equipment strategically rather than reacting to the next crisis. They could finally communicate daily expectations clearly to their teams.

Running through all of it was deliberate work to align the company’s existing values and purpose with daily behaviors on the floor. The cumulative effect reached well beyond the numbers: the leadership team felt more well-rounded and empowered, the firefighting culture gave way to planned, supervised production, and the company’s culture was strengthened by closing the gap between what it valued and how it worked every day.

The Full Result

Three measurable gains earned by leading differently, not by adding capacity.

52% to 91%
On-Time Startups

On-time startups improved 75%, from a 52% to a 91% average, as supervisors got back to leading and clear daily expectations replaced firefighting.

8%
Pounds Per Labor Hour

Pounds per labor hour rose 8% as a definitive operating system and clearer roles let frontline leaders plan labor and equipment instead of reacting.

17%
Overtime Reduction

Overtime fell 17% as the chaotic, reactive environment gave way to planned, supervised production.

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