The client, a leader in packaging solutions across North America, was looking to establish an Operational Excellence Program. However, both past performance and future projections for their Georgia plant were falling short of that goal.
Acknowledging the challenges ahead, the client engaged us to help develop and implement the program—starting with their Georgia facility.
At the time, the plant was struggling. Despite having what appeared to be sufficient labor, labor costs were high. Scrap rates led to excessive material usage, and the leadership team was stuck in a constant cycle of firefighting. Front-line leaders lacked real-time visibility into performance. They only learned of plant performance at the end of each week with information passed down to them rather than owned and understood firsthand.
Carpedia was engaged to improve performance, enhance labor efficiency and provide visibility into performance.
Solutions included:
- Introduced a “pit stop” approach to changeovers to reduce downtime and scrap
- Challenged the team to monitor machine speeds and investigate performance gaps
- Addressed operator compliance and reinforced accountability
- Improved visibility into performance using OEE and KPI training
- Implemented leadership standard work to ensure consistent process execution
- Increased active management through structured routines and oversight
- Identified capability gaps and developed a training program to enhance skills flexibility
The Results
- 2.4:1 ROI
- 56% improvement in productivity
- 48% reduction in scrap
- 44% improvement in uptime
- 62% improvement in OEE
