See new food packaging & processing solutions at PACK EXPO in Chicago
Discover new food packaging and processing innovations from 2,500+ suppliers, all under one roof at PACK EXPO International in Chicago.

SugarCreek: Where the rubber meets the road

The food manufacturer is taking the initiative to create a continuous improvement platform from scratch through leadership and employee engagement.

Zero-based analysis allows SugarCreek to identify opportunities for improvement. The processor compares proven historical rates to perfection and then identifies the gap to perfection as an opportunity. Graphic courtesy of SugarCreek.
Zero-based analysis allows SugarCreek to identify opportunities for improvement. The processor compares proven historical rates to perfection and then identifies the gap to perfection as an opportunity. Graphic courtesy of SugarCreek.

Craig Langhals is director of continuous improvement at SugarCreek, a diversified food manufacturer based in Ohio with six plants in the United States. The company is currently building a continuous improvement (CI) platform from scratch and utilizes Inductive Automation’s Ignition software as a tool to identify gaps and opportunities.

“We’re developing a standard performance system for the entire company to get consistency throughout the plants. Ignition development is the first principle of our performance system. The second principle is repeat daily review and response,” says Langhals.

The food processor trends most of its lines on throughput attainment using Ignition daily trends with a five-week rolling average. It has office reviews with the plants once a week to ensure daily meetings are happening and that it is maintaining a certain level of attainment and throughput. “Once a five-week trend becomes stagnant, it gets harder to make improvements,” Langhals explains. “Then we start coaching people on other tools for improvement.”

Before SugarCreek started its CI journey, it had a weekly ops review where plants reported their metrics. “With production, it was based on bill of material (BOM) and on Excel spreadsheets,” says Dan Stauft, director of operational technology (OT) at SugarCreek. “Everybody did math different ways, so we didn’t really have good measurements or data on how plants were implementing improvements.”

Today, SugarCreek can better track its success. The company looks at a four-week average, and, if it shows improvement, then it hit its goal, states Stauft. This is now SugarCreek’s corporate tool, and plants must report on it.

New food packaging & processing solutions, all at PACK EXPO in Chicago
Experience the cutting edge of food packaging and processing innovation at PACK EXPO International this November. See machinery and equipment in action, discover new technologies, and learn sustainable solutions from experts, all in one place.
Read More
New food packaging & processing solutions, all at PACK EXPO in Chicago
Back to Basics: Understanding Conveyors for Food Processing
Discover how modern conveyors enhance food processing—boost efficiency, ensure safety, and save space. Explore the latest tech and tips to optimize your operations.
Read More
Back to Basics: Understanding Conveyors for Food Processing