01
Changeovers That Eat the Shift
Every small change adds up to a lost shift.
We apply SMED so presses print, not wait.
Result: Up to 52% shorter changeovers.
Printing & Packaging Consulting
Printing and PackagingConsulting
Your presses are running. Your corrugators are running. So why is output still short of plan? Gemba Concepts finds where time, material and margin are quietly leaking — and fixes it alongside your team, until the results hold.
500+
Clients Served
1M+
Consulting Hours
40+
Industries
12+
Years Experience
Full-time on-site consultants
Shop floor execution, not just advisory
Measurable results within months
Trusted by 500+ manufacturers
What We Solve
Where Printing and Packaging Plants Quietly Lose Money
Most manufacturers lose 20-40% of their capacity to operational losses that have become part of everyday work. In printing and packaging, those losses hide inside short runs, frequent changeovers and material that sits in the wrong place for too long.
02
Printing Waste Nobody Owns
Makeready, rejects and reprints are lost margin.
We measure waste at source and fix the cause.
Result: 36.6% reduction in wastage.
03
Downtime You Cannot See
Hand-written logs miss micro-stops and waits.
We use TPM and live OEE to catch losses early.
Result: OEE lifted from 28% to 63%.
04
Material You Cannot Find
Reels in the wrong bay. Board bought twice.
We redesign storage and set inventory norms.
Result: 98.5% inventory accuracy, 12,000 sq ft freed.
05
Delivery Dates Promised on Guesswork
Sales commits. Production finds out later.
We back every date with real machine capacity.
Result: 40% faster throughput time.
06
An ERP That Doesn't Talk to the Floor
Data lives in the ERP. Decisions live on WhatsApp.
We connect floor to system and guide ERP setup.
Result: Production decisions run on real data.
Proven Results
Real Printing and Packaging Plants. Measurable Numbers.
These are implemented outcomes from packaging plants, not projection models.
Printing & Packaging
40% improvement in throughput time
- Throughput Time
- 40%
- Changeover Reduction
- 47%
- Wastage Reduction
- 36.6%
Changeover and wastage reductions backed by live OEE visibility.
Flexible Packaging
123% OEE improvement
- OEE Gain
- 123%
- Changeover Reduction
- 52%
- Timeline
- 8 Mo
OEE improved from 28.1% to 62.7% across printing and lamination lines, with cylinder changeovers cut from 95 to 45 minutes.
Greenfield Corrugated Packaging Plant
Zero rework from day one of operations
- Rework Hours
- 0
- To Rated Capacity
- 14 Wk
- Less Material Travel
- 22%
Layout, standard work and operator training were designed before the first order ran, so the plant reached rated capacity without firefighting.
Industrial Packaging
12,000 sq ft of storage space released
- Released
- 12,000 sq ft
- Inventory Accuracy
- 98.5%
- Faster Dispatch TAT
- 35%
Reels and board were re-slotted by consumption, with inventory norms and cycle counting built into daily routines.
Our Method
How We Work Inside Your Plant
01
Assessment & Diagnostics
A 2-4 day on-site study. We walk your pressroom, converting lines and stores, watch makeready and changeovers, and find where time, output and material are being lost.
02
Scope, Deployment & Commercials
Scope is defined from your data, not a template. Commercials are built on a clear ROI case, so the decision to proceed is grounded in numbers.
03
Current State Mapping & Baseline
Every process mapped, from order entry to dispatch. A signed performance baseline — OEE, changeover time, wastage, throughput time — against which every improvement is measured.
04
Proof of Concept, Implementation & On-Site Training
Solutions are proven on one line before full rollout. Implementation happens alongside your team. Training happens at the Gemba, in real conditions, under real pressure.
05
Sustenance & Audit Handover
Daily reviews, audit structures and performance dashboards are handed over to your team. We don't exit on a deadline. We exit when the results hold.
Why Gemba Concepts
Most Packaging Consultants Hand You a Report. We Hand You a Floor That Runs Better.
01
On the floor, every day
Our consultants work full-time at your plant. They stand at the press during makeready, at the corrugator during a grade change, and at dispatch when the truck is waiting. Findings come from observation, not questionnaires.
02
Commercials built on your numbers
Scope is defined from your data, not a template. Every engagement starts with an ROI case, so the decision to proceed rests on numbers, not faith.
03
Process first, system second
Most ERP projects in the packaging industry fail for one reason: they digitize a broken process. We fix the flow on the floor first, then help you choose and configure the right ERP to hold the gain — whether that is your existing system or our own platform, Gemba Connect.
04
We exit when results hold
Review systems and audit structures are built into your team before we step back. We don't leave on a deadline.
Industries We Serve
Every Segment of Printing and Packaging
The problems differ by segment, and so does the approach. We have worked inside:
Corrugated BoxesFlexible Packaging & LaminatesFolding CartonsLabelsRigid PackagingCommercial Printing
Client Voices
What operators say after we leave.
Trusted by Industry
500+
Industrial Businesses Across 3 Continents
Frequently asked questions
Let's Talk
Ready to Find Out What Your Presses Are Really Capable Of?
Let's identify where throughput, wastage and material cost are hiding in your packaging operations.
No commitment. A focused 30-minute conversation.
Speak directly with a senior printing and packaging consultant.
Specific insights based on your plant, your machines and your product mix.
Response within 24 hours.