THE CHALLENGE

Slaughtering and deboning of turkeys is the primary activity at this Cooper Farms division, which supplies other Cooper facilities with a variety of cuts for additional processing. The work is fast-paced (deboning lines run at 37 birds per minute), requires dexterity and training, and is complicated by the cold-room setting of many of the operations. Employee turnover is relatively high, and keeping workers trained is a challenge. “Some people are cut out to work in the cold, some not,” says Dale Hart, general manager. As a consequence, edible-meat losses, in evisceration operations for instance, were above industry averages and cut into profit margins. Recognizing the need to improve its processes, management began looking for a consulting firm that could increase the company’s competitiveness and “take us to another level of performance,” says Hart.

THE APPROACH

In 2004, MAGNET was invited to assist in the start-up of a new product line. Applying Lean Manufacturing techniques, MAGNET showed how the company could remove steps and streamline the process. “This small project was a good test, and we immediately saw the high potential of these concepts,” says Hart. Endorsing the approach, management underwent an off-site week of Lean 101 training, and eventually eight Lean events were completed in 2005. “The real selling point came after the first event, when management saw how proud the hourly members were to be part of a team, and how much they accomplished,” according to Hart. In selecting projects, individual supervisors were asked to identify processes that have always been a “thorn in your side, which you just don’t know how to tackle.” The gathering success with team-based Lean methods helped overcome the “proud spirit,” some individuals maintained, that they could tackle problems on their own. Removing bottlenecks and streamlining processes have been a big part of Cooper’s success, but so have improved training methods and materials. The company now uses many more visual aids, flip charts, and training books depicting desired results. Meat trimmings are audited to help in training and lend accountability. Also, in one project on shift changeover, movement of workers and job hand-offs were video taped helping to define new people and process flow.

CUSTOMER QUOTE

“Once MAGNET became involved here at Cooper Farms they began to understand what our whole business was about and saw all of our challenges. They brought hope to us after just a couple of victories. With their help it seems anything we touch we can make changes in and have significant improvements. We have six events scheduled here for 2006, and we will also be taking the concept to our headquarters location and doing events there.”
Dale Hart - General Manager

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