Minus a minute – plus millions: Omsk poultry meat producer increases output with the help of the federal Labor Productivity project

One of the largest agro–industrial complexes in the Omsk region, PRODO Sibirskaya Poultry Farm, summed up the results of its participation in the federal project "Labor Productivity" of the national project "Efficient and Competitive Economy". The company ranks second in the region in terms of production. With the support of experts from the Federal Competence Center (FCC), they optimized the production of thigh fillets, one of the key products in the revenue structure.

"The federal Labor Productivity project is based on the best international practices and our domestic experience from Alexey Gastev, the Central Institute of Labor and the School of Scientific Labor Organization that existed in the Soviet Union. In fact, we continue those traditions. Your results are remarkable. Now is not the time to relax – on the contrary, it is the moment to mobilize internal resources to do even more," said Kirill Samodinsky, Deputy Minister of Economic Development of the Omsk Region.

"We have achieved good results in increasing productivity at a particular site. With a high production base, a 10% increase is the optimal result. But even more importantly, there is an intangible effect: employees have gained the critical thinking that allows them not to stop there. I am sure that the results of the project will have a positive impact on the work and will be scaled to other production sites," said Mikhail Trapeznikov, Director of the Siberian Poultry Farm.

The company's working group was trained in lean manufacturing programs, visited the "Process Factory", and then, together with an expert from the FCC, conducted flow mapping, identified bottlenecks and found ways to solve them.

So, additional scales were installed at the laying site and two operations were combined – weighing takes place immediately after laying, without pauses. Another improvement was the conveyor that feeds fillets to the next stage of processing: it was structurally shortened, which accelerated the supply of raw materials. We also purchased a specialized sharpening machine, which simplified the preparation of the tool and improved the cutting quality.

These and other improvements have reduced the production time of thigh fillets by 11.5% – by about a minute per batch. Daily output increased by more than 770 kg. The total economic effect exceeded 63 million rubles.

"This project is a clear example of how the result consists of seemingly small improvements. We see a reduction in time — just a minute, but there is a whole range of activities behind it. And this approach needs to be replicated further: if even seconds can be saved in another department, then such seconds will eventually produce a significant, tangible result," said Sergey Trofimov, project Manager at the Federal Center for Labor Productivity Competencies.

The active phase of the project is designed for six months, but everything that has been developed during this time will continue to work after its completion – by the company itself. "Our feedback board continues to work – employees post comments and suggestions on it. The Working Group meets regularly in organized information centers. There are three of them in total. The company's information center reflects key indicators such as safety, production quality, and personnel, which are constantly kept up–to–date," said Elena Korobkova, head of the pilot project.

62 employees have been trained in lean manufacturing programs. The 5S system has been implemented, a project office has been created, and internal trainers have been trained. There are plans to replicate the experience gained not only in other areas of the poultry farm, but also in other enterprises of the company's group.

Participation in the project is free for businesses. You can apply on the Productivity website.RF.