Printing & Packaging Manufacturing
Improve OEE, Reduce Waste & Increase Throughput
Printing and packaging operations depend on speed, consistency, and efficient execution. Gemba Concepts helps manufacturers improve machine performance, reduce changeover losses, minimize material wastage, and strengthen production control through practical, shopfloor-driven improvements.
Current Industry Challenges
Low OEE and machine utilization
Unplanned downtime, slow speeds, and quality losses erode production capacity.
Long and inconsistent changeovers
Unstructured setups waste hours and create variability in production schedules.
High substrate, ink, and material wastage
Without waste tracking and process control, avoidable losses compound daily.
Print quality variations and rework
Inconsistent quality leads to customer complaints, rework, and material losses.
Production bottlenecks and scheduling issues
Imbalanced workflows and capacity constraints disrupt delivery commitments.
Limited visibility into shopfloor performance
Decisions are made reactively without real-time data on machine and process performance.
Frequent downtime and maintenance challenges
Breakdowns and reactive maintenance eat into production time and increase costs.
What We Work On
OEE & Equipment Performance
Improve machine utilization, reduce downtime, and increase production output.
Changeover Reduction (SMED)
Standardize setups and reduce changeover time to maximize available production hours.
Material Waste Reduction
Identify waste sources and improve process control to reduce substrate and ink losses.
Production Flow Optimization
Remove bottlenecks and improve workflow across printing, converting, and packaging operations.
Quality Management Systems
Strengthen inspection, defect tracking, and root cause analysis processes.
Production Visibility & KPI Systems
Create real-time visibility through performance dashboards and structured daily reviews.
TPM & Maintenance Systems
Improve equipment reliability through preventive maintenance and operator ownership.
Results Delivered
Up to 130%
OEE Improvement
Improve machine utilization and reduce downtime across printing lines.
25–50%
Changeover Time Reduction
Standardize setups to maximize available production hours.
20–40%
Material Wastage Reduction
Identify waste sources and improve process control.
Improved
Print Quality Consistency
Strengthen inspection and defect management systems.
Better
Production Visibility & Control
Real-time dashboards and structured daily reviews.
Higher
Throughput Without Additional Capacity
Unlock capacity through better flow and faster changeovers.
Stronger
Daily Management Systems
Build shopfloor discipline and structured performance reviews.
Frequently asked questions
Industrial Businesses Across 3 Continents