Del Real Foods

The situation

Del Real Foods, a division of Cardenas Markets, ran a USDA food manufacturing facility with a $98 million budget and 480 employees. The plant had been on a negative trend for two and a half years.

What Nacho did

• Took responsibility for organizing, directing and controlling every operational activity of the plant.
• Put production and hourly schedules in place that cut labor, overtime and double time.
• Set up a portion control program for all cooked proteins.
• Introduced a safety training program that lowered workers' compensation costs and accidents.
• Renovated plant infrastructure: wastewater treatment, water softening, boiler and hot water systems, and a new looped air system that stopped damage to sensitive equipment and improved sanitation.
• Improved the plant configuration layout for better product flow.
• Introduced the MAP management program to raise morale, accountability and productivity in the management team, keeping every team member who had been in place before.
• Renegotiated packaging, linen and corrugated contracts.

The result

$9.4 million of net income within 12 months, driven by better operational execution. Along the way: over $1 million saved on labor, over $450,000 through portion control (cutting food cost by more than 5.2%), over $300,000 in insurance premiums and $265,000 on contracts.