Multi-plant Packaging Company Drives Revenue Improvement by Boosting Line Speeds 15-20% Over Name Plate Capacity
Company Size
1,000+
Region
- America
Country
- United States
Product
- GainSeeker Suite
Tech Stack
- Real-time Data Collection
- Digital Equipment Integration
- Customized Dashboards
Implementation Scale
- Enterprise-wide Deployment
Impact Metrics
- Cost Savings
- Customer Satisfaction
- Productivity Improvements
Technology Category
- Analytics & Modeling - Real Time Analytics
- Application Infrastructure & Middleware - Data Visualization
- Functional Applications - Enterprise Resource Planning Systems (ERP)
Applicable Industries
- Packaging
Applicable Functions
- Business Operation
- Quality Assurance
Use Cases
- Predictive Maintenance
- Process Control & Optimization
- Real-Time Location System (RTLS)
Services
- Software Design & Engineering Services
- System Integration
About The Customer
The customer is a multi-plant packaging company that operates several manufacturing facilities. The company aims to harmonize quality and productivity across all its plants to create a more flexible supply chain capable of handling fluctuating demand. The Senior Quality Manager and Chief Information Officer play crucial roles in driving this initiative. The company has recently acquired six new plants, which are using different quality software systems, leading to performance gaps and inefficiencies. The company is committed to improving its operational efficiency, customer service, and overall productivity by standardizing its quality systems and leveraging real-time data collection and analysis.
The Challenge
The Senior Quality Manager for a multi-plant packaging company faced a significant performance gap between plants, with lower-performing facilities lagging by as much as 20% on key indicators such as line speed and quality levels. This disparity made it difficult to support the company's drive for a more flexible supply chain, as disparate systems hindered the ability to move products between plants to handle urgent orders. The underlying cause was identified as the use of different quality software systems and a lack of necessary infrastructure in poorer-performing facilities. The Chief Information Officer also recognized the need to standardize quality systems across newly acquired plants to minimize the cost of ownership and streamline support, despite anticipated resistance from staff.
The Solution
The solution involved deploying the GainSeeker Suite across all plants to standardize quality systems and enable real-time data collection. GainSeeker connects directly to digital equipment, saving time and eliminating clerical errors. Customized alarms and dashboards were implemented to help operators manage production quality and material use more effectively. The system provides color-coded alerts to guide operators on necessary actions and ties this information to employee performance bonuses. The deployment also included customized dashboards for weight tracking to compare material use against specifications, ensuring compliance and cost management. The CIO and Quality Manager leveraged their past successes with GainSeeker Suite to drive the adoption of the system across all plants, despite initial resistance from staff.
Operational Impact
Quantitative Benefit
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