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Improvement in Production Packaging results in Downtime Reduction and Output Increase",{"rendered":507,"protected":508},"\u003Ch2 class=\"wp-block-heading\" id=\"h-commissioning-and-management-of-a-fully-automatic-potato-flakes-packaging-line-continuous-improvement-in-production-packaging\">Commissioning and Management of a Fully Automatic Potato Flakes Packaging Line: Continuous Improvement in Production Packaging\u003C\u002Fh2>\n\n\u003Ch3 class=\"wp-block-heading\" id=\"optimizing-packaging-line-and-setting-new-standards-in-the-continuous-improvement-industry\">\u003Cstrong>Optimizing packaging line and setting new standards in the continuous improvement industry\u003C\u002Fstrong>\u003C\u002Fh3>\n\n\n\u003Cp>In the ever-evolving world of food production, our client, a renowned name in frozen fries, embarked on a new journey in 2022: the production of potato flakes.\u003C\u002Fp>\n\n\n\n\u003Cp>However, the transition wasn’t without its challenges. With our expertise, our client overcame these hurdles, optimizing their packaging line and setting new standards in the continuous improvement industry.\u003C\u002Fp>\n\n\n\n\u003Cp>Our client, while a master in frozen fries, was stepping into unfamiliar territory with potato flakes. The initial phase was riddled with challenges, from \u003Cstrong>unreliable machinery\u003C\u002Fstrong> to a \u003Cstrong>workforce unacquainted with the nuances of digital machinery\u003C\u002Fstrong>.\u003C\u002Fp>\n\n\n\u003Ch3 class=\"wp-block-heading\" id=\"challenges-faced\">\u003Cstrong>Challenges faced\u003C\u002Fstrong>\u003C\u002Fh3>\n\n\n\u003Cul class=\"wp-block-list\">\n\u003Cli>\u003Cstrong>Project Disruptions:\u003C\u002Fstrong> Key engineers, pivotal to the project, departed midway, causing significant delays and a disconnect with suppliers.\u003C\u002Fli>\n\n\n\n\u003Cli>\u003Cstrong>Machine Reliability:\u003C\u002Fstrong> Our client grappled with machinery that couldn’t meet production rates or maintain the quality standards their customers expected. This was uncharted territory for both our client and their machine suppliers.\u003C\u002Fli>\n\n\n\n\u003Cli>\u003Cstrong>Workforce Adaptation:\u003C\u002Fstrong> Long-time operators, accustomed to manual machinery, faced a steep learning curve with the new semi-automatic machines. Their pace of learning and resistance to change posed significant challenges.\u003C\u002Fli>\n\u003C\u002Ful>\n\n\n\u003Ch3 class=\"wp-block-heading\" id=\"our-strategic-approach\">\u003Cstrong>Our strategic approach\u003C\u002Fstrong>\u003C\u002Fh3>\n\n\n\u003Cp>Otofacto stepped in with a holistic strategy, focusing on both the technical and human aspects of the project:\u003C\u002Fp>\n\n\n\n\u003Cul class=\"wp-block-list\">\n\u003Cli>\u003Cstrong>Supplier Collaboration:\u003C\u002Fstrong> We engaged with suppliers across Europe, challenging them to enhance machine performance and meet stringent specifications.\u003C\u002Fli>\n\n\n\n\u003Cli>\u003Cstrong>Stakeholder Coordination:\u003C\u002Fstrong> Ensuring seamless communication between internal teams and external partners was paramount.\u003C\u002Fli>\n\n\n\n\u003Cli>\u003Cstrong>Continuous Training:\u003C\u002Fstrong> We prioritized operator training, introducing them to best packaging practices and the intricacies of the new machinery.\u003C\u002Fli>\n\n\n\n\u003Cli>\u003Cstrong>Embracing Continuous Improvement:\u003C\u002Fstrong> Deployment of industry-leading practices like 5S and SMED, coupled with the introduction of a PML1 system and advanced training for maintenance technicians, set the stage for sustained growth.\u003C\u002Fli>\n\u003C\u002Ful>\n\n\n\u003Ch3 class=\"wp-block-heading\" id=\"h-outstanding-results-nbsp-of-continuous-improvement-solutions\">\u003Cstrong>Outstanding Results of Continuous Improvement Solutions\u003C\u002Fstrong>\u003C\u002Fh3>\n\n\n\u003Cp>Our collaborative efforts bore fruit:\u003C\u002Fp>\n\n\n\n\u003Cul class=\"wp-block-list\">\n\u003Cli>A remarkable increase in packaging output, from 480 Tons\u002Fmonth in September 2022 to 2100 Tons\u002Fmonth by June 2023.\u003C\u002Fli>\n\n\n\n\u003Cli>Quality enhancements, notably addressing sealing issues with finished product bags.\u003C\u002Fli>\n\n\n\n\u003Cli>A significant reduction in downtime, dropping from 450 hours\u002Fmonth to a mere 120 hours.\u003C\u002Fli>\n\u003C\u002Ful>\n\n\n\n\u003Cp>In the realm of maintenance and optimizing machine performance to improve productivity, our expertise shines through.\u003C\u002Fp>\n\n\n\n\u003Cp>Continuous Improvement in Production Packaging results in downtime reduction (-73%) and packaging output increase (+338%)\u003C\u002Fp>\n\n\n\n\u003Cfigure class=\"wp-block-image size-full is-resized\">\u003Cimg loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"576\" src=\"https:\u002F\u002Fstaging-admin.cbtw.tech\u002Fwp-content\u002Fuploads\u002FPotato-Flakes-gluten-free-substitute-1024x576-1.jpg\" alt=\"Continuous Improvement Solutions for Food & Beverage Industry: Commissioning and Management of a fully Automatic Potato Flakes Packaging Line\" class=\"wp-image-2371\" style=\"width:401px;height:auto\" srcset=\"https:\u002F\u002Fstaging-admin.cbtw.tech\u002Fwp-content\u002Fuploads\u002FPotato-Flakes-gluten-free-substitute-1024x576-1.jpg 1024w, https:\u002F\u002Fstaging-admin.cbtw.tech\u002Fwp-content\u002Fuploads\u002FPotato-Flakes-gluten-free-substitute-1024x576-1-800x450.jpg 800w, https:\u002F\u002Fstaging-admin.cbtw.tech\u002Fwp-content\u002Fuploads\u002FPotato-Flakes-gluten-free-substitute-1024x576-1-100x56.jpg 100w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \u002F>\u003C\u002Ffigure>\n\n\n\u003Ch3 class=\"wp-block-heading\" id=\"h-digital-transformation-in-manufacturing\">\u003Cstrong>Digital transformation in manufacturing\u003C\u002Fstrong>\u003C\u002Fh3>\n\n\n\u003Cp>Discover what Continuous Improvement Solutions can bring to your industry. Our client’s success story is a testament to our commitment to driving \u003Ca href=\"https:\u002F\u002Fcollaborationbetterstheworld.com\u002Fservices\u002Fsmart-industrial-solutions\u002F\">digital transformation in the manufacturing industry\u003C\u002Fa>.\u003C\u002Fp>\n",false,{"rendered":510,"protected":508},"\u003Cp>Commissioning and Management of a Fully Automatic Potato Flakes Packaging Line: Continuous Improvement in Production Packaging Optimizing packaging line and setting new standards in the continuous improvement industry In the ever-evolving world of food production, our client, a renowned name in frozen fries, embarked on a new journey in 2022: the production of potato flakes. […]\u003C\u002Fp>\n",2370,"open","standard",{"_acf_changed":508,"content-type":8,"inline_featured_image":508,"footnotes":8},[43],[],[518],137,[520],136,[522,502,523,524,525,526,527,528,529,530],"post-2369","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-case-studies","cbtw_industries-manufacturing","cbtw_services-smart-industrial-solutions",{"authors":8,"article_authors":508,"direct_external_link":8,"post_region":532,"layout_builder":533},"global",[534],{"acf_fc_layout":535,"title":195,"ui_v2":536,"short_description":537,"cbtw_related_group_filters":538,"items":508,"link":543,"hubspot_form_id":8,"mainPostId":496,"region":532},"block_insights",true,"Access related expert insights",{"cbtw_related_category_filter":539,"cbtw_related_tag_filter":540,"cbtw_related_industry_filter":541,"cbtw_related_service_filter":542},[221,197],[],[],[],{"title":544,"url":545,"target":546},"View all 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