Case Studies

Helping a large integrated corrugated manufacturer improve productivity

Opportunity
A large integrated corrugated manufacturer was experiencing lost productivity and downtime due to missed splices. Each time a splice was missed the entire corrugator would need to shut down, so that the end of one roll of paper could be attached to the new roll.

Solution
The corrugated manufacturer looked to Adalis to assess the situation, identify the cause and present a solution. Adalis conducted a thorough analysis of the splicing process and determined that the rolls were not spliced correctly. Adalis technical staff put together a phased plan for improving the process and worked directly with the manufacturer to train personnel on standard operating procedures to sustain the improvements.

Results
The process improvements identified by Adalis coupled with on-site training resulted in a 75 percent reduction in missed splices, increasing productivity by 45 minutes per eight-hour shift. Based on an average opportunity cost of $1,500 per hour, 45 minutes per shift can total more than $60,000 per month or $720,000 per year.