ReliabilityX Delivers $8M Margin Gain on Bosch Line for The Little Potato Company

Case Study: ReliabilityX Delivers $8M Margin Gain on Bosch Line for The Little Potato Company

The Challenge

The Bosch Line at The Little Potato Company’s Edmonton facility was falling short of its design capacity. Machines were underperforming, costs were escalating, and the workforce lacked the skills to identify and resolve operational issues. The result was inefficiency, excessive waste, and a growing gap between potential and actual output.

Leadership recognized the urgency. To restore throughput and reduce cost of goods sold, they needed a partner who could deliver both technical solutions and cultural change.

The Solution

ReliabilityX responded with a comprehensive, hands-on strategy. Their team began with a full assessment of equipment and processes, identifying key defects and inefficiencies. Initial cleaning events restored machinery to optimal condition, while targeted training equipped the workforce to solve problems proactively.

Key initiatives included:

• Restoring equipment performance through defect identification and cleaning protocols
• Training staff to recognize and resolve operational issues in real time
• Implementing center lining and operational standards to stabilize production
• Driving accountability and consistency across the line

This approach combined technical rigor with workforce empowerment, creating a foundation for sustainable reliability.

The Results

The transformation was significant and measurable:

• Throughput increased by 65 percent across 5.3 million units
• Cost of goods sold dropped from $4.97 to $3.47 per unit, adding $8 million to margin
• Quality rejects decreased by 64 percent
• Over-weight product was reduced by 60 percent

The Bosch Line now operates with greater precision, lower costs, and a workforce capable of sustaining performance improvements.

Conclusion

ReliabilityX helped The Little Potato Company turn a struggling production line into a high-performing asset. By restoring equipment, building workforce capability, and standardizing operations, they delivered measurable results and long-term value.

If your plant is facing similar challenges, ReliabilityX can help. Contact us at ask@reliabilityx.com or click here.