Unblocking a packaging line by rebuilding the information system
A Fortune 400 manufacturer in South Carolina — packaging equipment area.
The problem
The packaging line was a bottleneck. The information systems feeding the plant production system down to the equipment were overly complex and unreliable, so production conversions were slow and error-prone.
What we did
Led a complete redesign of the information flow between the production system and the packaging equipment — removing unnecessary code and redundant displays, and adding sequential step verification so each production conversion was quick and unambiguous.
The outcome
The packaging area went from a recurring bottleneck to running with 30% excess capacity — more throughput, fewer failures, faster changeovers.
- 70%unnecessary code eliminated
- 40%redundant displays removed
- 30%excess capacity after redesign