Maintaining precise alignment—known as the centerline—is critical for consistent product quality in high-speed production. Yet, McCain’s traditional process relied on manual checks, lacked upstream visibility, and offered no historical data trail. TribalScale helped redesign that model by deploying a Digital Centerline Management (DCL) system: a real-time, visual platform that guides operators with live data, streamlines adjustments, and powers predictive analytics.
Impact Delivered
Challenge
Three persistent issues were slowing production:
Zero visibility into upstream or downstream centerline adjustments, leaving operators reactive instead of proactive.
Difficulty detecting when environmental variability or input quality (like raw potato inconsistencies) impacted alignment.
No historical tracking, depriving teams of the insights needed for continuous improvement and predictive maintenance.
McCain needed a scalable, low-friction tool to empower operators with timely alignment feedback—supported by contextual insights and future-ready data.
Solution
TribalScale led weekends‑in‑action discovery sessions with operators, shift managers, and supervisors—not just to understand workflows, but to co-create improvements. In two intensive DDD and Event Storming workshops, we defined the ‘as-is’ problems and visualized a purpose-built ‘to-be’ DCL experience. Features were prioritized using MoSCoW (Must-Have, Should-Have, etc.) and Value vs. Effort frameworks to ensure speed and impact.
The team built an intuitive digital solution, layered onto existing systems, minimizing disruption while maximizing value.
Live Operator Dashboards — Installed 60-inch screens with real-time visuals of centerline status and actionable alerts.
Tablet Interfaces — Made alignment data accessible on the go for operations staff.
Real-Time Alerts — Notified operators immediately when threshold deviations occurred, enabling fast corrections.
Predictive Cues — Layed the groundwork for future AI-driven guidance by capturing data across variables (inputs, tooling, ambient conditions).
Tools and Technologies Used:
Microsoft Power Apps
Microsoft Azure
Power Platform
Jquery
Outcome
From sluggish, paper-based checks to a dynamic, data-driven interface—McCain's production lines now reflect real-time intelligence. TribalScale’s work didn’t just deliver a tool; it elevated operational thinking, embedded agile collaboration, and equipped McCain with both the data and culture to sustain continuous improvement across plants worldwide.
Why It Matters
In high-volume manufacturing, every second matters. Moving centerline checks from reactive and manual to live and visual means fewer stoppages, higher fidelity, and empowered teams. It shows how digital transformation—when focused on operational muscle—becomes a multiplier for quality, efficiency, and resilience.