The Background
Through ongoing work with an existing customer, the Phenix team saw firsthand the operational challenges putting one of the customer’s manufacturing facilities at risk. By partnering closely with the customer and implementing packaging line optimization, workflow improvements, and operator training, performance improved, inefficiencies were reduced, and operations stabilized. Phenix helped transform a facility that was once near shutdown into one of the customer’s top-performing plants—without purchasing new equipment or increasing headcount.
The Challenge
Despite having the capacity to produce 20,000–25,000 pounds of product per shift, the facility consistently produced only 12,000–15,000 pounds, and at its lowest point, was at risk of shutting down.
Key Challenges
- Significant packaging equipment downtime and inefficiencies when loading product.
- Excessive employee movement and lost production time.
- Lack of defined line leadership and accountability.
- Inconsistent production workflows that negatively affected manufacturing efficiency.
Our Approach
Phenix took a holistic approach, rather than focusing solely on equipment installation, by evaluating the customer’s entire packaging operation. Working alongside plant leadership, maintenance, and operators, the team assessed workflows, equipment performance, material flow, changeover procedures, and day-to-day production practices to identify the root causes of inefficiency.
The team focused on practical operational improvements that would maximize the performance of the food manufacturer’s existing equipment, workforce, and production processes.
Our Solutions
After completing the operational assessment, the Phenix team implemented a series of targeted improvements designed to eliminate inefficiencies, improve production flow, and maximize the performance of the customer’s existing packaging operation.
Operational Optimization
Phenix analyzed workflows at the operator level, identifying small inefficiencies that created significant production losses over time. Every aspect of the operation was evaluated, from changeover habits to product staging to end-of-the-line processes.
Leadership and Accountability
Phenix worked alongside management and maintenance to improve communication while helping establish dedicated line leads. This created greater ownership, accountability, and consistency across production shifts.
Improved Material Staging Strategy and Workflow Design
Phenix recommended and assisted in reorganizing how packaging materials were staged around equipment to create an ergonomic workflow. By reducing unnecessary reaching, turning, walking, and material retrieval, operators were able to remain focused on production while minimizing wasted motion.
Training and Culture
Through months of hands-on coaching on the production floor, the Phenix team worked with the customer to reinforce standardized work practices and helped build a culture focused on efficiency, consistency, accountability, and continuous improvement.
The Results
Key Performance Results
- Production output increased by 2–3×.
- Packaging line downtime decreased by 30–50%.
- Workflow improvements resulted in 3.5 million additional packages produced.
- Changeover times improved from 15–20 minutes to approximately 5 minutes.
- Lost indexes during printed film roll changes were reduced from 15+ indexes to just 1–2.
- The facility transitioned from operating at a loss to becoming one of the top-performing plants in the customer’s network.
Same people. Same equipment. Better results.
Even small improvements, such as reducing five minutes of lost time during a film roll change, created a significant impact when multiplied across every production shift. Rather than relying on capital investment or additional labor, operational optimization transformed the facility into one of the customer’s best-performing manufacturing plants.
Interested in exploring what’s possible for your operation? Contact us to start the conversation.