Bay Valley Foods

Bay Valley Foods leverages Factory MES across its entire plant network.

Born from a spin-off of Dean Foods and Del Monte, Bay Valley Foods is a leading provider of shelf-stable foods. Currently a subsidiary of TreeHouse Foods, Inc., Bay Valley operates 18 plants and generates $1.5 billion in annual revenue.

“The move to real-time intelligence and structured review processes has created a model for continuous improvement that has become embedded into the day-to-day workings of our plant floor. I believe this is the quickest route to capitalizing on our latent human capital potential.”

George Jurkovich, Senior Vice President Operations

Challenge

Bay Valley Foods was facing spiraling material costs and increasing competition in its private-label food business. The company needed to gain enough efficiency to increase capacity, streamline costs, and avoid unnecessary capital expenditures.

Solution

The company chose to invest in Factory MES — a Manufacturing Execution System designed for process manufacturers.

Result

Real-time intelligence and structured reviews are now embedded into the day-to-day workings of the plant floor. Each plant has also achieved measured productivity gains within eight weeks of implementation. Bay Valley fully expects a 5-10% improvement across the network in a year, which translates to between $2.5 million and $5 million annually across the entire plant network.

Topline Results

OEE improvement from a low of 56% to consistently over 75%.
On track to save between $2.5 and $5 million with increased operational efficiency.