Guest Post: Campbell Soup’s Supply Chains of the Future

Temple U. Professor Misty Blessley  looks at an interesting supply chain issue.

Supply and demand markets are always evolving, requiring firms to regularly assess and adjust their operations and supply chains to maintain efficiency. Food manufacturers like Campbell Soup Company are adapting by closing some facilities, opening new ones, and expanding existing plants to optimize production.

Campbell, known for its iconic canned soup, is investing $230 million to enhance its operations and supply chains. This investment aims to drive growth while fostering agility, flexibility, and cost-effectiveness. Campbell Soup Company also includes brands such as Pepperidge Farm, V8, and Swanson and has grown to be one of the largest processed food companies in the U.S. In a recent Supply Chain Dive article, Campbell highlighted the company’s ongoing efforts evaluate optimization opportunities to build its supply chain of the future.

Supply chains can be complex and non-linear, as illustrated in your Heizer/Render/Munson text in Figure 11.1. Due to Campbell’s diverse product range, it manages multiple supply chains.

Campbell is closing its Pacific brand organic soup plant due to aging leased buildings that are unsuitable to meet future demand. Consequently, soup and broth production will be relocated, and plant-based beverage production will be transferred to co-manufacturers. Additional changes to the supply chain network aimed at increasing plant efficiency at select U.S. plants include increasing aseptic (sterile canning process) soup production, adding potato chip kettles, and expanding tortilla chip capacity.

Beyond enhancing plant efficiency, Campbell plans to boost capacity for some of its most popular brands. The production of Late July brand tortilla chips will be expanded, and the company will offer new Goldfish varieties, leveraging Goldfish as the fastest-growing cracker brand in the category.

Classroom discussion questions:
1. Why is a SWOT analysis integral for Campbell to build its “supply chain of the future”?
2. Campbell emphasizes competitiveness (“We are growth-minded, take bold actions, move fast, and play to win”) and creativity (“We innovate and find solutions to continuously improve”) as two of its five core values. How do these values manifest in their redesigned operational footprint?

OM in the News: Cooking Up Productivity During the Recession at Campbell Soup

The recession slashed 8.5 million jobs in the US and slowed companies investment plans–but it also pushed up productivity growth (see Ch.1). This is good news for corporate profits , and bad news for people waiting for recession-casuality jobs to come back. Annual growth in productivity, or how much output is produced in an hour of work, averaged 3.4% in the last 5 quarters…all while sales dropped another 9% during that period.

The latest  Businessweek (Nov.29-Dec.5, 2010) highlights the drive at Campbell Soup to ask “employees to help them save cash by working smarter with existing technology.”  “The reward for increased efficiency is a stable job and more business”, says Campbell’s VP-Supply Chain. His team is working to reinvent how the company makes soup.

Like carmakers who use a common chassis for multiple cars and then differentiate, Campbell is now doing the same instead of using a unique recipe for each soup. With a common chicken broth base, the firm differentiates with seasonings, meat, and vegetables.

Daily worker-manager meetings also raise productivity, with nitpicky efforts to save time, money, and effort. Operators and mechanics started numbering each gasket to speed repairs, cut windows into machine covers so they could watch for signs of wear, color-coded handles to lower confusion in settings. All these small changes added up to an increase to 85% operating efficiency, up from 75% three years ago. Each 1% gain means $3 million more in operating profits.

Businessweek also notes that UPS trucks now carry devices that track how many left turns its drivers have to make. The new system helps drivers optimize routes and will save 1.4 million gallons of fuel per year.

Discussion questions:

1. How does productivity improvement impact the re-creation of jobs?

2. Why are employees so important in productivity gains?