Reduced Downtime by 35% in a Multi-Line Packaging Facility

Results Snapshot

Challenge

Production output fluctuated heavily between shifts due to manual tracking, inconsistent reporting, and lack of real-time performance visibility.

Approach

• Implemented real-time stop detection and automated downtime logging.
• Standardized shift dashboards with live KPIs and loss tracking.
• Introduced short-interval control meetings based on real data.
• Linked downtime events to operational and changeover patterns.

Outcomes

• Unplanned downtime reduced by 35% within the first phase of implementation.
• More predictable daily output and improved planning accuracy.
• Data-driven culture shift toward continuous improvement and Lean execution.