Church & Dwight Case Study
Church & Dwight Case Study
Church & Dwight deployed OneTrack's AI agents at its 1.1 million square foot York distribution facility and saw ROI in under 5 months, with $287,000 in annual cost savings, an 84% reduction in safety events, and 120+ hours saved weekly by automating break and lunch compliance.
The Challenge
At over 1.1 million square feet, Church & Dwight's York site is the company's largest facility, shipping 50% of all domestic volume. But with 250 operators, 96 forklifts, and a nonstop pace, leaders struggled with visibility into everyday operations.
Manual tracking methods made it nearly impossible to catch exceptions in real time, especially when it came to break compliance, load quality, and coaching consistency.
"We knew there was some abuse with 15-minute breaks, but no hard data. You'd look at system gaps and think, how is the break the same length as lunch? That's not right."
At the same time, supervisor bandwidth was stretched thin. Coaching moments were missed. Performance reviews lacked structure. And root causes were left unknown.
The Solution
Church & Dwight deployed OneTrack with a focus on improving safety. But within weeks, OneTrack's AI agents became the operational game-changer.
Today, OneTrack automates daily workflows once done manually (or not at all):
"The agents don't just find issues, they give our supervisors the exact coaching points and even recognize wins. We were losing 120 hours a week just on extended breaks. Now, OneTrack flags violations and sends them directly to supervisors. That alone pays for OneTrack."
The Results
Since rolling out OneTrack, Church & Dwight has seen immediate results across compliance, productivity, and quality:
"We used to go off gut feel. Now we have data, and it's automatic. The system even picked up a legitimate idle event where an operator was helping clean a spill. OneTrack told us to thank him. That's next level."
Church & Dwight realized $287,000 in annual cost savings, driven by recovered gap time. The facility had been losing 120+ hours a week on extended breaks before OneTrack automated break and lunch compliance tracking. Flagging break violations alone pays for OneTrack, according to Logistics Manager Dylan O'Connor.
Church & Dwight saw measurable ROI in under 5 months. OneTrack was deployed with an initial focus on improving safety, but within weeks its AI agents began automating daily operational workflows across compliance, productivity, and quality.
Church & Dwight deployed OneTrack Operational Intelligence, a set of AI agents built for operations. The system tracks break and lunch compliance via video and movement data, automatically sends supervisor alerts for policy violations, and generates weekly safety reports and new-hire 60-day reviews. It also records loading footage automatically to protect operators and pinpoint carrier-related damage.
The York site is Church & Dwight's largest facility at over 1.1 million square feet and ships 50% of all domestic volume. It runs with 250 operators and 96 forklifts at a nonstop pace, which made manual exception tracking nearly impossible before OneTrack.