Flexible packaging is one of the biggest manufacturing industries in the US, with over 30 billion in annual sales and growing, the industry is projected to 3x within a span of 5 years. Unlike most manufacturing industries, flexible packaging has always been driven by advancements in industry-specific machine technology. These advancements in packaging capabilities bear the need to provide more customized product specifications to customers. Things such as intelligent sensor films, film barriers, authentication seals, RFID technology and much more have increased the complexity in job processes causing an increase in compromised promise dates.
Many industry leaders in flexible packaging have now found success in the adoption of advanced production scheduling software and manufacturing execution software to aid in the increased demand for customization and process.
The case study below highlights one of the many flexible packaging manufacturers that utilize WorkClout as their primary tool to plan, execute and measure their production process. This study contains data recorded over a period of 2 months before implementation and 2 months after the adoption and implementation of WorkClout.
WorkClout is a top-rated advanced production scheduler (APS) and manufacturing execution software (MES).
Read more here: Capterra
Company A is a mid-sized flexible packaging company
Before using WorkClout, Company A’s production process was managed via paper and excel. This results in a severe lack of insight into the overall quality rate during production, leading to an increased number of job rework that was required to meet customer standards. Below are the reasons why the quality rate was a relevant issue.
A sample size of 66 jobs was followed and analyzed over a period of 1 month before implementation to establish a baseline metric of current production state. There were three specific metrics that we looked at.
Looking at the data from a holistic perspective you can easily infer that these metrics were really hurting the productivity of Company A’s production process as a whole.
The delays equate to a compounding average loss of $81,852 annually, assuming average hourly labor costs and total average jobs completed annually.
By leveraging WorkClout’s visual job management, production schedule, and operator portal. Company A’s employees would be able to streamline each job’s production process into one platform, enabling all employees the ability to instantly view job progression and next steps.
After observing and documenting these metrics over a period of 1 month. We began tracking the same metrics after implementation with WorkClout and below are the results.
A sample size of 57 jobs was followed and analyzed over a period of 1 month after implementation to compare results after using WorkClout for a period of time. There were three specific metrics that we looked at.
After implementing and having used WorkClout you can see that almost all categories in which delays occurred saw an immediate improvement.
Company A has been able to reduce its average lead time by over 5 days by using WorkClout to streamline communication, plan production, and execute with precision.
By reducing the number of delays throughout production, Company A has increased profit margin by over $76,464 annually.
Documented and Written by the WorkClout data team in 2019. Company A