Low OEE and machine utilization
Unplanned downtime, slow speeds, and quality losses erode production capacity.
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.
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Pain Point Section
Common Industry Challenges
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.
Solution Section
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 Section
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.
Industry Case Studies
Execution Stories from This Industry
Explore real transformations delivered in similar operating environments.
Packaging and Label Printing
OEE More Than Doubled in Twelve Months
A national printing and packaging operation improved OEE by 123% in 12 months while reducing changeover time by 47% and wastage by 36.6%.
OEE: +123%Changeover time: -47%Wastage: -36.6%
Key Levers
- Implemented press- and shift-level OEE dashboards to move reviews from opinion to data.
- Filmed changeovers and applied SMED using observable facts instead of memory.
- Ran daily floor-level 5-Why reviews to convert recurring stops into closed corrective actions.
- Improved MTTR and MTBF discipline so breakdowns cost less and repeat less.
Packaging Manufacturing
A New Plant, Built Right the First Time and Commissioned on Schedule
A family-owned packaging exporter designed and commissioned a growth-ready greenfield facility on schedule, built exactly to drawing with no design change during construction.
Commissioning: On scheduleExport scale: 23 markets servedHandling: AMR + articulated forklifts
Key Levers
- Sized future capacity and specified machinery for projected growth.
- Designed L-shaped material flow and inventory norms for RM, WIP, and FG.
- Built automation in from day one with articulated forklifts, AMR systems, and rack-supported mezzanine storage.
- Validated operations-fit and issued detailed cost estimate before build start.
Industrial Packaging
Less Raw-Material Space, More Boxes per Shift
A Fortune 1000 packaging operation cut raw-material storage from 50,000 to 38,000 sq ft while output increased from 12 to 25 boxes per shift.
RM storage: 50k -> 38k sq ftProduction: 12 -> 25 boxes/shiftFlow: U-shaped movement
Key Levers
- Ran value-stream mapping and five-year capacity evaluation.
- Designed a U-shaped flow to reduce travel and crossing.
- Applied selective and cantilever racking based on load profile.
Trusted by
500+
Industrial Businesses Across 3 Continents
Testimonials
What Our Clients Say
Wires & Cables ManufacturingIndia
“Their hands-on approach has resulted in practical and tailored solutions that have reduced wastage, optimized processes, and increased overall equipment effectiveness (OEE).”
Jainam Deliwala
Director
Rolliflex Pvt Ltd
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Wires & Cables ManufacturingIndia
“Their hands-on approach has resulted in practical and tailored solutions that have reduced wastage, optimized processes, and increased overall equipment effectiveness (OEE).”
Jainam Deliwala
Director
Rolliflex Pvt Ltd
Steel Tubes & Pipes ManufacturingIndia
“Their dedicated team efforts and innovative solutions backed by thorough data analysis helped us deliver our operational targets.”
Mahaveer Agarwal
Managing Director
Suncity Metals & Tubes Pvt Ltd
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FMCGIndia
“They successfully developed KPIs that provide us with clear insights into our organizational performance and enabled us to make data-driven strategic decisions.”
Aju Jacob
Joint Managing Director
Synthite Industries Pvt Ltd
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Lubricants & Automotive SolutionsIndia
“Gemba Concepts demonstrated exceptional expertise in reducing operational bottlenecks, optimizing stock movement, and implementing data-driven inventory management.”
Sanjeev Wangoo
Executive Director – Group Supply Chain Management
Veedol Corporation Limited
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Steel & Tubes ManufacturingIndia
“Gemba Concepts demonstrated exceptional expertise in implementing lean methodologies, reducing operational inefficiencies, and streamlining warehouse management practices.”
Rahul Agarwal
COO
Mahalakshmi Profiles Pvt Ltd
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Chemicals ManufacturingIndia
“The team has showcased professionalism, collaborative approach, and reliability, making them a trusted partner.”
Aniket Shah
Director
Crystal Quinone Pvt Ltd
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Food & Bakery ManufacturingIndia
“Their dedicated team efforts and innovative solutions backed by thorough data analysis helped us deliver our target of manpower optimization.”
Aditya Dalmia
Managing Director
SAA Vishnu Bakers Pvt Ltd
%2FAditya%20Dalmia.png&w=3840&q=75)
Spice ManufacturingIndia
“Their strength in collaborating with cross-functional teams, addressing challenges and providing viable solutions makes them recognized process-driven experts.”
Hari Swani
Director – Operations
Swani Spice Mills Pvt Ltd
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Plastic ManufacturingKenya
“Their expertise was particularly evident in areas such as data management and visualization, manpower and electricity cost reduction, and the development of effective operations review systems.”
Sachin Patel
CEO
Dentex Industries Limited
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Cable ManufacturingIndia
“They successfully combined technology and data-driven solutions with Lean principles to deliver sustainable results.”
Ayush Shah
Director
Prem Cables Pvt Ltd
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Pharmaceutical ManufacturingIndia
“The GCPL team demonstrated a profound and intrinsic understanding of our unique operational challenges.”
Naishadh Shah & Krishna Kumar
MD & COO
Swiss Parenterals / Eris Lifesciences
%2FNaishadh%20Shah.png&w=3840&q=75)
Food & Spice ProcessingKenya
“Their involvement led to significant process optimization, measurable improvements, and enhanced efficiency across our operations.”
Shiv Dhanda
CEO
Spice World Limited
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Packaging ManufacturingIndia
“Gemba Concepts demonstrated a deep understanding of lean manufacturing principles and applied them to drive improvements in operational efficiency and productivity.”
Puneet Agarwal
Director
Manjushree Innovations Pvt Ltd
%2FPuneet%20Agarwal.png&w=3840&q=75)
Printing & PackagingIndia
“Their innovative solutions have significantly enhanced our printing and packaging operations by reducing machine downtime and increasing productivity.”
Priyata Raghavan
Dy CEO
Sai Packaging Company
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Retail & Supply Chain OperationsIndia
“The development and implementation of a Warehouse Management System greatly improved material traceability, inventory control, and process visibility.”
Ajay Kumar Challa
VP – IT & HR
RSB Retail India Ltd
%2FAjay%20Kumar%20Challa.png&w=3840&q=75)
Wires & Cables ManufacturingIndia
“Their hands-on approach has resulted in practical and tailored solutions that have reduced wastage, optimized processes, and increased overall equipment effectiveness (OEE).”
Jainam Deliwala
Director
Rolliflex Pvt Ltd
Steel Tubes & Pipes ManufacturingIndia
“Their dedicated team efforts and innovative solutions backed by thorough data analysis helped us deliver our operational targets.”
Mahaveer Agarwal
Managing Director
Suncity Metals & Tubes Pvt Ltd
FMCGIndia
“They successfully developed KPIs that provide us with clear insights into our organizational performance and enabled us to make data-driven strategic decisions.”
Aju Jacob
Joint Managing Director
Synthite Industries Pvt Ltd
Lubricants & Automotive SolutionsIndia
“Gemba Concepts demonstrated exceptional expertise in reducing operational bottlenecks, optimizing stock movement, and implementing data-driven inventory management.”
Sanjeev Wangoo
Executive Director – Group Supply Chain Management
Veedol Corporation Limited
Steel & Tubes ManufacturingIndia
“Gemba Concepts demonstrated exceptional expertise in implementing lean methodologies, reducing operational inefficiencies, and streamlining warehouse management practices.”
Rahul Agarwal
COO
Mahalakshmi Profiles Pvt Ltd
Chemicals ManufacturingIndia
“The team has showcased professionalism, collaborative approach, and reliability, making them a trusted partner.”
Aniket Shah
Director
Crystal Quinone Pvt Ltd
Food & Bakery ManufacturingIndia
“Their dedicated team efforts and innovative solutions backed by thorough data analysis helped us deliver our target of manpower optimization.”
Aditya Dalmia
Managing Director
SAA Vishnu Bakers Pvt Ltd
Spice ManufacturingIndia
“Their strength in collaborating with cross-functional teams, addressing challenges and providing viable solutions makes them recognized process-driven experts.”
Hari Swani
Director – Operations
Swani Spice Mills Pvt Ltd
Plastic ManufacturingKenya
“Their expertise was particularly evident in areas such as data management and visualization, manpower and electricity cost reduction, and the development of effective operations review systems.”
Sachin Patel
CEO
Dentex Industries Limited
Cable ManufacturingIndia
“They successfully combined technology and data-driven solutions with Lean principles to deliver sustainable results.”
Ayush Shah
Director
Prem Cables Pvt Ltd
Pharmaceutical ManufacturingIndia
“The GCPL team demonstrated a profound and intrinsic understanding of our unique operational challenges.”
Naishadh Shah & Krishna Kumar
MD & COO
Swiss Parenterals / Eris Lifesciences
Food & Spice ProcessingKenya
“Their involvement led to significant process optimization, measurable improvements, and enhanced efficiency across our operations.”
Shiv Dhanda
CEO
Spice World Limited
Packaging ManufacturingIndia
“Gemba Concepts demonstrated a deep understanding of lean manufacturing principles and applied them to drive improvements in operational efficiency and productivity.”
Puneet Agarwal
Director
Manjushree Innovations Pvt Ltd
Printing & PackagingIndia
“Their innovative solutions have significantly enhanced our printing and packaging operations by reducing machine downtime and increasing productivity.”
Priyata Raghavan
Dy CEO
Sai Packaging Company
Retail & Supply Chain OperationsIndia
“The development and implementation of a Warehouse Management System greatly improved material traceability, inventory control, and process visibility.”
Ajay Kumar Challa
VP – IT & HR
RSB Retail India Ltd
Wires & Cables ManufacturingIndia
“Their hands-on approach has resulted in practical and tailored solutions that have reduced wastage, optimized processes, and increased overall equipment effectiveness (OEE).”
Jainam Deliwala
Director
Rolliflex Pvt Ltd
Steel Tubes & Pipes ManufacturingIndia
“Their dedicated team efforts and innovative solutions backed by thorough data analysis helped us deliver our operational targets.”
Mahaveer Agarwal
Managing Director
Suncity Metals & Tubes Pvt Ltd
FMCGIndia
“They successfully developed KPIs that provide us with clear insights into our organizational performance and enabled us to make data-driven strategic decisions.”
Aju Jacob
Joint Managing Director
Synthite Industries Pvt Ltd
Lubricants & Automotive SolutionsIndia
“Gemba Concepts demonstrated exceptional expertise in reducing operational bottlenecks, optimizing stock movement, and implementing data-driven inventory management.”
Sanjeev Wangoo
Executive Director – Group Supply Chain Management
Veedol Corporation Limited
Steel & Tubes ManufacturingIndia
“Gemba Concepts demonstrated exceptional expertise in implementing lean methodologies, reducing operational inefficiencies, and streamlining warehouse management practices.”
Rahul Agarwal
COO
Mahalakshmi Profiles Pvt Ltd
Chemicals ManufacturingIndia
“The team has showcased professionalism, collaborative approach, and reliability, making them a trusted partner.”
Aniket Shah
Director
Crystal Quinone Pvt Ltd
Food & Bakery ManufacturingIndia
“Their dedicated team efforts and innovative solutions backed by thorough data analysis helped us deliver our target of manpower optimization.”
Aditya Dalmia
Managing Director
SAA Vishnu Bakers Pvt Ltd
Spice ManufacturingIndia
“Their strength in collaborating with cross-functional teams, addressing challenges and providing viable solutions makes them recognized process-driven experts.”
Hari Swani
Director – Operations
Swani Spice Mills Pvt Ltd
Plastic ManufacturingKenya
“Their expertise was particularly evident in areas such as data management and visualization, manpower and electricity cost reduction, and the development of effective operations review systems.”
Sachin Patel
CEO
Dentex Industries Limited
Cable ManufacturingIndia
“They successfully combined technology and data-driven solutions with Lean principles to deliver sustainable results.”
Ayush Shah
Director
Prem Cables Pvt Ltd
Pharmaceutical ManufacturingIndia
“The GCPL team demonstrated a profound and intrinsic understanding of our unique operational challenges.”
Naishadh Shah & Krishna Kumar
MD & COO
Swiss Parenterals / Eris Lifesciences
Food & Spice ProcessingKenya
“Their involvement led to significant process optimization, measurable improvements, and enhanced efficiency across our operations.”
Shiv Dhanda
CEO
Spice World Limited
Packaging ManufacturingIndia
“Gemba Concepts demonstrated a deep understanding of lean manufacturing principles and applied them to drive improvements in operational efficiency and productivity.”
Puneet Agarwal
Director
Manjushree Innovations Pvt Ltd
Printing & PackagingIndia
“Their innovative solutions have significantly enhanced our printing and packaging operations by reducing machine downtime and increasing productivity.”
Priyata Raghavan
Dy CEO
Sai Packaging Company
Retail & Supply Chain OperationsIndia
“The development and implementation of a Warehouse Management System greatly improved material traceability, inventory control, and process visibility.”
Ajay Kumar Challa
VP – IT & HR
RSB Retail India Ltd
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Frequently Asked Questions (FAQ's)
Frequently Asked Questions
Common questions printing and packaging manufacturers ask about operational improvement.
What is OEE in printing and packaging?
OEE (Overall Equipment Effectiveness) measures machine performance by tracking availability, speed, and quality losses — helping identify where production capacity is being lost.
How can changeover time be reduced?
Through standardized setup processes, SMED (Single-Minute Exchange of Die) implementation, and better planning and preparation.
Why is material wastage high in printing operations?
Common causes include setup losses, process variation, handling issues, and lack of systematic waste tracking and measurement.
How can print quality be improved?
By strengthening quality checks, process controls, defect management systems, and root cause analysis of recurring quality issues.
How quickly can improvements be seen?
Most printing and packaging operations start seeing measurable improvements within 4–8 weeks of implementation.
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