CASE STUDIES
PRE-LAUNCH
SITUATION
Hungryroot was in its developmental Pre-Launch Phase when Mistalink was recommended and hired as support and as someone that has gone through these decision phases.
THEIR NEED
Support the "industrialization" of the developed recipes for customer success and anticipation on what production would look like as retailers are onboarded and production, throughput & demand would grow.
PRIMARY SERVICES PROVIDED
- Packaging consultation for the meal-kits and heating instructions for customers facing end products
- Evaluated the production set up strategy to determine in-house vs outsourced production.
- Processing Equipment for increased demand.
- Facility & Food Safety recommendations to be able to fulfill retailers' requirements
- Sourced all-natural shelf-life enhancements to support freshness for a successful supply chain
RESULTS
Hungryroot created successful partnerships with regional & national retailers as well as kept up with rapid growth for direct-to-consumer as well as retail.
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OPTIMIZE & OVERCOME
SITUATION
Freshdirect was in the design phase for their new flagship facility and was looking for efficiencies in their MTO (Make-to-Order) Production Stations.
THEIR NEED
Develop a "Single Cell Manufacturing" slicing & confirmation station with at least
10% productivity gains for
the Deli operation.
PRIMARY SERVICES PROVIDED
- Analyze production waving set up (MRP logic) and consolidate to lower product handling for each production wave.
- Design ergonomic production station that allows for 1-& 2-person staffing.
- Align room design with station layout for efficient flow.
- Create Raw Material flow from warehouse to production rooms including food Safety Prevention Step, WIP storage and ERP system driven replenishment flow to each station.
- Smart automation for Finished Product flow out of the department.
- Develop High Speed Solution for select high volume products with automatic weight and label application flow in a "batched" production environment.
RESULTS
Enhancements yielded 1.5h product handling time reduction per FTE (Full Time Employee) shift and a overall efficiency gain of 18-25% depending on station type. Overall department labor efficiency gains where in the low 30% mark from old to new facility.
GROWTH & EXPANSION
SITUATION
Freshdirect-NYC's first and biggest e-grocer outgrew their Long Island City Start-UpPlant and was looking to build a new Headquarter housing their complete internal manufacturing as well as their main warehousing and distribution center.
THEIR NEED
Re-envisioning the manufacturing process, building production capabilities, process and design layouts to 3.5x growth projection, decide on software solutions for the different area of operation and their integration, move complete operation from building to building with minimal customer impact.
PRIMARY SERVICES PROVIDED
- Design 120K square feet layout for food manufacturing space producing via MTO (Make-to-Order) and MTS (Make-to-Stock) production strategies.
- Production layouts for RTE (Ready-to-Eat) and RTC (Ready-to-cook aka raw meat & seafood handling) & Transitional production area (Kitchen "raw-in & RTE out") & food safety & HACCP flows.
- SAP ERP enhancements for production wave logic's, Production planning & SKU set up.
- Participation in 3-way software integration between SAP (ERP), Manhattan Associates (WMS) & Intelligrated WES systems including Design requirements & UAT.
- Involved in 2-year build phase with permanent onsite office.
- Participated in management & staff training material.
- Development & execution of transition scenarios, building move-out/in.
RESULTS
Achieved desired output capabilities and 15-20% laborefficiencies for comparable areas. Successful move Kitchen of 180 personnel, 200 truckloads of materials, equipment & small wares from Sunday postproduction moveout to Wednesday afternoon production start in new facility. Smooth "parallel transition phasing" for MTO areas while operating departments in both facilities to support pick & pack, dispatch & transportation transition.
Extensive learnings & solution finding overcoming challenges that surfaced post
move in warehouse operations.