Turning Underperformance into Profit: The Little Potato Company’s Multivac Line Rebuilt
The Problem
The Little Potato Company’s Multivac production line in Edmonton, Alberta was operating far below its intended capability. What should have been a stable, high‑performing asset had become a bottleneck. Equipment was not running at design rate, minor defects were compounding into major losses, and operators did not have the tools or training to identify issues before they escalated. The line was experiencing chronic downtime, inconsistent performance, and rising operational costs.
These issues were not isolated. They were symptoms of deeper systemic problems. Variability in equipment condition, lack of standardized operating practices, and limited workforce capability were creating a cycle of firefighting instead of controlled, predictable production. Leadership recognized that without a structured, reliability‑driven intervention, the plant would continue to fall short of customer demand while absorbing unnecessary cost.
The goal was clear. Restore throughput. Reduce waste. Build a workforce capable of sustaining long‑term reliability. Do it in a way that created measurable financial impact.
The Solution
We partnered with The Little Potato Company to deliver a comprehensive, hands‑on transformation of the Multivac line. Our approach was designed to stabilize the equipment, strengthen the workforce, and eliminate the operational barriers that were limiting performance.
Our strategy included:
-Conducting a full mechanical and operational assessment to uncover hidden defects, process losses, and sources of variability that were driving downtime and inefficiency.
-Executing targeted cleaning and restoration events to return equipment to optimal operating condition and eliminate the chronic issues that had become normalized.
-Delivering specialized training that equipped operators and technicians to identify, troubleshoot, and resolve issues at the source instead of relying on reactive maintenance.
-Implementing center lining and operational standards that locked in consistency, reduced drift, and created predictable, repeatable performance.
-Coaching leaders and frontline teams to reinforce reliable behaviors, maintain process control, and sustain improvements long after the engagement ended.
This was a structured reliability intervention that combined technical precision with cultural alignment. The plant gained not only restored equipment performance but also a workforce that understood how to maintain and grow that performance every day.
The Results
The improvements were immediate, measurable, and financially significant. The Multivac line shifted from a chronic constraint to a reliable, high‑performing asset.
-Throughput increased by 56%, expanding annual capacity from 4 million to 10.5 million units
-Yield improved by 10%, generating $377,000 in savings
-Labor savings totaled $417,000 through improved flow and reduced intervention
-Material waste was reduced by 58%
-Cost of Goods Sold per unit decreased by $0.17
These results were not temporary. They were the outcome of restored equipment, standardized processes, and a workforce capable of sustaining reliability. The Little Potato Company now operates with greater efficiency, lower cost, and a stronger foundation for future growth.
Conclusion
We helped The Little Potato Company transform a struggling production line into a stable, predictable, and profitable operation. By restoring equipment condition, elevating workforce capability, and implementing operational standards, we delivered sustainable results that continue to scale across the facility.
If your plant is experiencing throughput loss, rising costs, chronic downtime, or instability on critical equipment, you do not have to accept those conditions as normal. A structured reliability approach can change the trajectory of your performance.
Schedule a free consultation and see what ReliabilityX can unlock for your operation.