Process Training & Operational Alignment for Multi-Site Pet Food Manufacturer

Client
North American pet food manufacturer responsible for operating several production facilities.

The Challenge

The Pet Food Manufacturer was looking to improve their process consistency, operational understanding, and product quality control across their multiple manufacturing facilities. The leadership recognized that many managers and quality personnel had limited experience working within the direct production environment, which created barriers to comprehend all variables involved and the complexities of the extrusion process, as well as their direct impact on produced product quality.

Their main objectives included:

• Increasing consistency in the extrusion process across sites
• Improving control in quality and density of the product
• Increased internal knowledge of maintenance and process troubleshooting
• Creating a better understanding of how the complete Extrusion facility operates
• Increasing awareness of modern day processing technology and opportunities for optimally processing

Ultimately, the goal of the Pet Food Manufacturer was to have a common operational language and an operational vision to be shared across the entire organization of their respective employees.

The 1 Solution Group Approach

1 Solution Group partnered with the Pet Food Manufacturer to develop and implement an extensive extrusion process training program that was created for lead plant managers and operational supervisors from the various North American manufacturing plants.

The program included a technical component, a hands-on demonstration component, and collaborative problem-solving sessions.

Key Elements of the Engagement

Process Training for Site Leaders

Lead managers from multiple North American facilities participated in focused training designed to build a stronger understanding of extrusion operations and system integration.

Classroom Instruction

The participants were instructed using an organized delivery method that provided information on:

• Extrusion equipment functionality
• Process flow and system integration
• Mechanical and thermal energy inputs
• Key variables that affect the quality of the product

Hands-On Operational Training

Participants rotated through hands-on training stations focused on:

• Equipment operation
• Maintenance practices
• Troubleshooting techniques
• Process adjustments and their impact on product characteristics

Collaborative Process Discussions

Interactive sessions allowed Pet Food Manufacturer leaders to:

• Evaluate their current processes
• Identify improvement opportunities
• Align on best practices across sites

These discussions resulted in the creation of a common understanding of potential methods to optimize processes throughout the organization.

Results and Value to the Client

• Improved Process Understanding: Participants better understood how both mechanical energy and thermal energy inputs affect product results, enabling operators to make more accurate and timely process adjustments.
• Increased Energy Efficiency: By better understanding the purpose and balance of energy inputs within the extrusion process, teams identified opportunities to reduce unnecessary energy consumption.
• Improved Product Consistency: Participants learned the importance of uniform drying and process control, helping reduce variability and lowering potential food safety risks.
• Stronger Technical Support Network: Leadership created direct contact with experts and technical resources, which allowed them to access information, parts, and problem-solving support faster than before.
• Organizational Alignment: Perhaps most importantly, the engagement helped create a unified process vision across all sites, improving communication, consistency, and long-term operational strategy.

Outcome

The Pet Food Manufacturer has enhanced its internal knowledge, developed cross-site coordination, and trained its leadership in the skills necessary for optimizing Extrusion Operations for maintaining reliability in their products.