Case Studies Multi-plant Packaging Company Drives Revenue Improvement by Boosting Line Speeds 15-20% Over Name Plate Capacity

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	Multi-plant Packaging Company Drives Revenue Improvement by Boosting Line Speeds 15-20% Over Name Plate Capacity

Multi-plant Packaging Company Drives Revenue Improvement by Boosting Line Speeds 15-20% Over Name Plate Capacity

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
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. Read More
About 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. Read More
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. Read More Log in to view content
Contents

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

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.

About 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.

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.

Impact #1	The deployment of GainSeeker Suite enabled the company to harmonize quality across all plants, reducing the cost of ownership and streamlining support.
Impact #2	Real-time data collection and customized alarms improved production quality management, allowing operators to take immediate action based on color-coded alerts.
Impact #3	Customized dashboards for weight tracking helped the company manage material use more effectively, ensuring compliance and cost savings.

Impact #1

The deployment of GainSeeker Suite enabled the company to harmonize quality across all plants, reducing the cost of ownership and streamlining support.

Impact #2

Real-time data collection and customized alarms improved production quality management, allowing operators to take immediate action based on color-coded alerts.

Impact #3

Customized dashboards for weight tracking helped the company manage material use more effectively, ensuring compliance and cost savings.

Benefit #1	Line speeds increased by 15-20% above name plate capacity.
Benefit #2	Performance gap between plants reduced by up to 20%.

Benefit #1

Line speeds increased by 15-20% above name plate capacity.

Benefit #2

Performance gap between plants reduced by up to 20%.

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Overview

Multi-plant Packaging Company Drives Revenue Improvement by Boosting Line Speeds 15-20% Over Name Plate Capacity

Operational Impact

Quantitative Benefit