How Real-Time Production Monitoring Helped Putter’s Pickles Reduce Labor Costs and Improve Production Efficiency

Daniel, John, and Boudjema wanted a solution that would allow them to measure productivity without requiring large investments of time and resources to implement.

“Most systems we looked at were complex, less accessible, and difficult to use. In contrast, Worximity’s real-time production monitoring software was affordable and user-friendly. It offered everything small to mid-sized manufacturers like us need.”

He adds that the 30-day proof of concept approach helped to solidify the decision.

“The proof of concept confirmed that the system was easy to integrate into our operations. This put to rest any fears that the software would take up too much of our time and resources.”

Recognizing that the quickest and most effective way to boost revenue was by increasing volume while controlling costs, Boudjema leveraged Worximity to gain deeper insights into his operations.

“The software is very detailed but, there is a focus on the essentials. I can sort by downtime, equipment, by day, product type, format, and so on. And I can set production targets. I enter my production objectives into the system and monitor them by the minute. I know immediately when my line stops. Worximity keeps me up to date without constantly being on the floor. I can monitor everything that’s happening remotely and in real-time.”

Short production stoppages may seem insignificant, but on a production line, these micro stops can add up.

“Our production line is linear, but it’s very long. If a worker stops at one end of the line for maybe 10 seconds, it cascades down the line. By the time it reaches the other end, that stop lasted 45-50 seconds easily. Over a 10-hour day, stopping for 10 seconds here, 20 seconds there, adds up and dramatically affects schedules and costs.”

Armed with insights from Worximity’s software, Boudjema is much more confident when attending senior management meetings.

“Before, I didn’t have any concrete data to present. Now I come prepared with numbers and answers about production performance. This has greatly facilitated decision-making and even changed project priorities.”

He adds that the software assists in making informed business decisions by providing clear ROI projections.

“I can quantify our losses related to product falling on the floor, demonstrate potential savings if we invest in new equipment and quickly answer questions about labor, the profitability of investments, etc. My arguments are supported with data.”

For manufacturers experiencing or positioning themselves for growth, production insight is only part of the equation. With limited resources, small to mid-size organizations often benefit from outside experience to help identify and implement broader improvement opportunities. Recognizing that Worximity’s Continuous Improvement team offered a wealth of experience, Boudjema was eager to leverage their expertise.

“I’ve been in the industry for 21 years and I always appreciate a fresh perspective. Worximity has helped many manufacturers make meaningful improvements and I value that insight. I’ve tried other consultants, but they weren’t focused on the issues that mattered to us. Or they worked remotely, and we might see them once a year. Worximity didn’t just pitch software and say see you later. Their CI consultant is with us twice a week and we work on the essentials together. He’s my right-hand man, and I find that incredibly valuable.”