Food Packaging Manufacturer Needed to Ramp Up Production


About the opportunity

Rev1 Packaging designs and manufactures certified, 100% compostable, and recyclable molded fiber food packaging products. They focus on key fit-for-use capabilities to meet each customer’s unique packaging needs while accelerating global change to protect our earth’s resources. Rev1 Packaging was in the start-up stage and working on ramping-up its operation.
The Challenge
The process to manufacture the product is not a simple one and the business has limited resources. The manufacturing consists of several processes including thermoforming, die cutting, and vacuum dry system. The operation currently has 2 assets in place and the goal is to have 12 operational by Q1 2023. The main issue the business is facing is getting machines up and running and running consistently.
We had to quickly help this client improve their results and used the following three-phase approach:

• Phase 1 – Equipment troubleshooting: We started by identifying and tackling issues with the equipment causing downtime or defects. We continued by collaborating with the team to develop corrections or modifications to the equipment to avoid defective parts and interruptions.
• Phase 2 – Problem-solving : We installed basic problem-solving devices such as production control boards and visual management boards. This enabled us to focus on the immediate issues but also to understand the mid-term trends of performance so that the team could start addressing those proactively.
•Phase 3 – Process documentation: We proceeded to develop documentation such as standard work procedures and Failure Modes & Effects Analysis to help the organization continue to execute and have the references for troubleshooting future issues.

Rev1 Packaging was able to increase and maintain a higher production rate with better quality. Among the results that Rev1 Packaging accomplished as part of our engagement are:

• Improved yield rate by 70% (from 10-20% to > 90%) for number one obstacle equipment.
• Improve throughput in production cycles by 300%.
•Improved overall yield by 60%.

About Us
We help manufacturers achieve and sustain operational cost reductions of 20%+, improve on-time delivery to 99%+, and reduce defects to improve product quality to 99%+. These changes help our clients grow company profit margins by up to 25%.
We have developed and used a proven approach to ensure manufacturers achieve and sustain significant performance improvement. Our consultants have over 15 years of experience working with manufacturers and developing their capabilities.
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