Riverside Plant Reclaims Control and Cuts Costs with ReliabilityX

Case Study: Riverside Plant Reclaims Control and Cuts Costs with ReliabilityX

The Challenge

The Riverside Plant in Wisconsin was facing mounting operational pressure. Throughput was stagnant, costs were rising, and defective packaging was a recurring issue. The plant’s culture was reactive, and its systems lacked the structure needed to drive consistent performance. With an average Overall Equipment Effectiveness (OEE) of just 47 percent, the operation was falling short of its potential.

Leadership knew they needed more than incremental change. They needed a complete reset.

The Solution

ReliabilityX brought a structured, hands-on approach to the Riverside Plant. Their team designed and implemented tailored processes focused on operational excellence. Training was a core component, equipping both leadership and frontline teams with the tools to shift from reactive habits to proactive execution.

Key initiatives included:

• Building a customized system to eliminate inefficiencies and improve throughput
• Delivering targeted training to elevate problem-solving and accountability
• Embedding predictive practices to reduce defects and drive consistency
• Aligning plant-wide efforts around measurable performance goals

This was not a one-size-fits-all solution. It was a strategic rebuild, grounded in the realities of day-to-day operations.

The Results

The transformation was immediate and measurable:

• OEE jumped from 47 percent to 65 percent in the first year
• Current OEE averages 73 percent, with further gains underway
• The plant saved $1 million in manufacturing variances in year one, and is on track to save another million this year

The Riverside Plant is no longer reacting to problems. It is driving performance with confidence, clarity, and control.

Conclusion

ReliabilityX helped the Riverside Plant move from stagnation to sustained success. Their approach combined strategic systems with direct engagement, resulting in stronger operations and significant cost savings.

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