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.
Printing & Packaging Consulting. Done on Your Shop Floor.
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
Trusted by
500+
Industrial Businesses Across 3 Continents
Full-time on-site consultants
Shop floor execution, not just advisory
Measurable results within months
Trusted by 500+ manufacturers
Why Gemba Concepts
Most Packaging Consultants Hand You a Report. We Hand You a Floor That Runs Better.
Packaging consulting services usually stop at the recommendation. Ours start there. Gemba Concepts was founded by former Toyota professionals, and for over a decade we have worked inside printing units, corrugation plants and flexible packaging converters — where the losses actually happen.
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.
Process first, system second
Most ERP projects in the packaging industry fail for one reason: they digitise 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.
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.
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.
Changeovers That Eat the Shift
Shorter runs and more SKUs mean more plate, cylinder, die and grade changes. Each one feels small. Added up across a month, they are a second shift you are paying for and not getting.
How Gemba Helps
We apply SMED to separate internal and external setup, standardise makeready and pre-stage materials, so presses spend more time printing and less time waiting.
Printing Waste Nobody Owns
Makeready sheets, trim, colour rejects and reprints get accepted as the cost of doing business. They aren't. They are margin going into the scrap bin.
How Gemba Helps
We measure wastage at source, by machine, job and shift, then fix the causes: standard settings, first-piece approval and process controls that reduce printing waste for good.
Downtime You Cannot See
If downtime is logged by hand at the end of the shift, you are managing yesterday's guesses. Micro-stops and waiting for material never make it into the report.
How Gemba Helps
We implement TPM and live OEE tracking, so losses show up while there is still time to act.
Material You Cannot Find
Reels in the wrong bay, board bought twice, inks expiring on the shelf. Poor packaging material management ties up working capital and floor space, and still leaves the press waiting.
How Gemba Helps
We redesign storage, set inventory norms and build packaging inventory management discipline that keeps stock visible, accurate and moving.
Delivery Dates Promised on Guesswork
Sales commits a date. Production finds out later. Planning runs on experience and phone calls, not on actual machine capacity.
How Gemba Helps
We build a capacity-based production planning process, so every commitment is backed by a real slot on a real machine.
An ERP That Does Not Talk to the Floor
Many plants already have an ERP system for the printing industry. Very few use it to run production. The data lives in the system, while the decisions still happen on WhatsApp.
How Gemba Helps
We map how your floor actually works, close the gaps between process and system, and guide ERP selection or reconfiguration for printing production management that runs on real data.
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.
Proven Results
Real Printing and Packaging Plants. Measurable Numbers.
These are implemented outcomes from packaging plants, not projection models.
40% improvement in throughput time
40%
Throughput Time
47%
Changeover Reduction
36.6%
Wastage Reduction
Changeover and wastage reductions backed by live OEE visibility.
123% OEE improvement
123%
OEE Gain
52%
Changeover Reduction
8 Mo
Timeline
OEE improved from 28.1% to 62.7% across printing and lamination lines, with cylinder changeovers cut from 95 to 45 minutes.
Zero rework from day one of operations
0
Rework Hours
14 Wk
To Rated Capacity
22%
Less Material Travel
Layout, standard work and operator training were designed before the first order ran, so the plant reached rated capacity without firefighting.
12,000 sq ft of storage space released
12,000 sq ft
Released
98.5%
Inventory Accuracy
35%
Faster Dispatch TAT
Reels and board were re-slotted by consumption, with inventory norms and cycle counting built into daily routines.
Testimonials
What Our Clients Say
Wires & CablesIndia
“Our lines were running but output kept falling short. Gemba came in, worked directly on the floor, and fixed what we had stopped questioning. OEE improved, wastage dropped, and the results have held.”
Mr. Jainam Deliwala
Director
Rolliflex Cables Private Limited
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1/5
Industries We Serve
Every Segment of Printing and Packaging
The problems differ by segment, and so does the approach. We have worked inside:
Corrugated Boxes
Flexible Packaging & Laminates
Folding Cartons
Labels
Rigid Packaging
Commercial Printing
Frequently Asked Questions (FAQ's)
Questions Packaging Manufacturers Ask Us
Straight answers on what an on-site printing and packaging consultant does, how results are measured, and where ERP fits in.
What does a printing and packaging consultant actually do on-site?
They work inside your plant, not from a conference room. They observe makeready, changeovers, material movement and dispatch, measure where output and material are lost, then implement the fixes alongside your supervisors and operators — from standard work to OEE tracking.
How is Gemba Concepts different from other packaging consulting companies?
Our consultants stay on the floor full-time until results are stable, and every engagement is tied to a signed baseline. Improvement is measured against numbers you have agreed to, not claimed after the fact.
Which segments of the packaging industry do you work with?
Corrugated boxes, flexible packaging and laminates, folding cartons, labels, rigid packaging and commercial printing. The problems differ by segment, and so does the approach.
Can you help us reduce printing waste without buying new machines?
Yes. Most printing waste comes from makeready, settings variation and weak first-piece control, not from the machine itself. Our Printing & Packaging case study shows a 36.6% reduction in wastage.
Do you help with ERP for the packaging industry?
Yes. We fix planning, material and production flows first, then guide ERP selection, reconfiguration or implementation so the system reflects how your floor actually runs. Where it fits, we also offer our own platform, Gemba Connect.
We already have an ERP. Will you ask us to replace it?
Not by default. During assessment we map what your current system covers on the floor and what it misses. The recommendation follows your data.
How long before we see results?
The diagnostic takes 2–4 days on-site. Measurable improvements in changeover, wastage and OEE typically show within the first few months of implementation, tracked against the signed baseline.
What size of plant do you usually work with?
Printing and packaging manufacturers from ₹50 Cr turnover upward, across India, the Middle East and Africa.
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.
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