Automated Packaging Services

The Challenge

• Order levels had increased to a level that was difficult for operations to support delivery commitments, and due date performance was deteriorating
• There appeared to be a lack of bag manufacturing capacity
• There were many conflicting measures promoting local optimisation in operations.

How we helped

• Gained consensus on the current situation and core problem, and agreed the design of the new operations solution
• Educated and trained key staff
• Developed the stock replenishment processes for stock bags and stock film
• Replaced the existing local measures with global ones.

Results

• Full buy-in and commitment of the Production Operations Manager and Production Services Manager t the new operations way of working
• Bag manufacturing capacity has been increased by more than 10 per cent
• Film buffers implemented, supporting greater than 99.7 per cent due date performance
• Lead time of two weeks for plain bags and three weeks for printed bags.

“This project has focused us on key issues, at a time when the company’s growth does not look like diminishing…I am very impressed by Levee’s common sense approach.”
Peter Wylie, Director and General Manager