Improving Process Efficiency and Product Consistency Through Corporate Extrusion Training

The Challenge

Cargill sought to strengthen operational consistency and process understanding across several manufacturing sites. Leadership recognized that differences in operational knowledge, maintenance practices, and process control were creating opportunities for inefficiencies and product variability.

Several site leaders and quality team members also came from non-production backgrounds, creating a need for a clearer understanding of how extrusion systems operate and how individual process variables affect product outcomes.

Cargill’s goals included:

• Improving process consistency and product quality control
• Developing preventative maintenance practices to improve equipment uptime
• Training leadership teams to detect extrusion wear and operational issues earlier
• Building foundational knowledge of the complete extrusion process
• Helping teams understand how each system component impacts product density and performance
• Introducing modern processing technologies and optimization opportunities

The company wanted to equip its managers with the technical knowledge needed to support stronger, more consistent operations across multiple sites.

The 1 Solution Group Approach

1 Solution Group partnered with Cargill to deliver a comprehensive extrusion process training program designed for lead site managers representing multiple North American facilities.

The training program combined technical instruction, hands-on operational learning, and collaborative problem-solving.

Key Elements of the Engagement

Corporate Process Training Program

Lead managers from several Cargill production facilities participated in a structured training program focused on strengthening technical process knowledge and operational decision-making.

Classroom-Based Technical Instruction

Participants received detailed instruction on:

• Extrusion system components

• Process flow and equipment integration

• Operational best practices

• Key variables that impact product quality and density

Hands-On Equipment and Maintenance Training

Training groups rotated through practical stations focused on:

Equipment operation

• Preventative maintenance practices

• Identifying extrusion wear

• Troubleshooting common operational issues

Collaborative Process Discussions

Interactive discussions allowed Cargill leaders to review their existing processes, compare operational approaches between sites, and identify opportunities for improved process alignment moving forward.

Results & Measurable Benefits

The program delivered significant improvements in operational efficiency, product consistency, and cross-site alignment.

50% Increase in Productivity

Participants achieved a 50% improvement in productivity, measured as working hours per metric ton of product produced.

Reduced Product Giveaway

Cargill experienced a 2% reduction in shrink, representing a 25% decrease in product giveaway caused by finished product moisture falling below target levels.

Significant Reduction in Non-Quality Costs

Improved process control led to a $100,000 per month reduction in Cost of Non-Quality (CONC) associated with out-of-spec product requiring rework.

Stronger Technical Support Network

Participants established direct relationships with process experts, creating an ongoing resource for troubleshooting, operational support, and process optimization.

Unified Operational Vision

The training program helped align teams across multiple facilities, establishing a shared process strategy and operational standards across Cargill sites

Outcome:

Through targeted process training and cross-site collaboration, Cargill strengthened operational expertise, improved manufacturing efficiency, and significantly reduced costs related to product variability and rework.