Goals
The customer approached us because they were pursuing the following goals in order to enhance their production flow:
1. to increase the productivity of the packaging assembly line, which so far had been handled in a totally manual way.
2. to reduce materials that are harmful for the environment such as polystyrene protections (applied BY HAND and not recyclable)
3. to cut down deviations and waste (according to the concepts of MUDA & MURA) to a minimum in order to save time and manage consumption in efficient ways
4. to reduce returns to a minimum
5. to improve the appeal of the packaging and therefore the product image since customer's associate a high quality packaging with a high quality product
Solution
In order to meet the customer's needs the following solution was implemented:
1. Panotec provided a fully customized and fully automated system to produce and close fefco type 201 boxes.
2. All the polystyrene protections were replaced by honeycomb cardboard blocks applied automatically on all 4 sides of the box.
3. By implementing this solution along with the production of a tailor-made box just-in-time, thus reducing the amount of time allocated for packaging operations, productivity increased significantly (35''/box).
4. The box is provided with an additional protection and returns due to transport damage were significantly reduced from 12 to only 1 per month.
5. Effective improvements could be achieved in terms of product image (a high quality box for a high-quality product) and operational requirements (storage, handling and transport protection).