Continuous Improvement Project Identifies 31% Boost in Productivity

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The Challenge

TriVista was retained by a private equity firm that invested in a label and packaging business. The business had recently merged with a competitor, and our team was tasked with measuring and improving the Overall Equipment Effectiveness (OEE) of their flexographic printing and rewind departments.

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Our Approach

• Completed OEE assessment and baseline for flexo, rewind, and digital departments
• Implemented shop floor KPIs to measure and analyze top sources of machine downtime
• Eliminated or offloaded all external processes from machine operators
• Completed current state value stream map and identified top waste/opportunities
• Rebalanced labor in the value stream creating better flow
• Implemented daily production schedules and hour by hour downtime tracking

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The Results

We identified a 31% improvement in printing productivity and increased finishing productivity by 68%. We decreased WIP by 88% and improved scheduling capacity by 4x.