Breaking the Misconceptions: Process Optimization Unlock 30% Potential Capacity

Did you know most food manufacturing plants leave 15 to 30 percent of capacity and profit on the table? It is rarely because of bad equipment or bad people, but because of how work is designed and executed.

In this episode, our AI hosts, Alice and James, kick off our Breaking Misconceptions series and unpack six false beliefs that quietly erode stability and performance, including filling every second, blaming workers instead of fixing system design, assuming SOPs guarantee performance, letting instructions go stale, believing digital tools cannot integrate, and accepting downtime as inevitable. They close with practical examples of low cost pilots using visual work instructions and a small set of sensors, plus the operational rigor needed to cut waste, reduce errors, and recover capacity.

• (00:00) - The hidden capacity loss in food manufacturing
• (03:42) - Misconception: filling every second boosts productivity
• (05:32) - Misconception: our employees just don’t like work
• (06:45) - Misconception: procedures guarantee performance
• (08:01) - Misconception: old work instructions are enough
• (09:40) - Misconception: digital tools are too hard to implement
• (11:21) - Misconception: downtime is inevitable
• (12:32) - The core takeaway

Articles mentioned:
Breaking the Misconceptions Part 1: Misconceptions About Process Optimization

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