Greif, a global leader in industrial packaging, faced persistent challenges in reducing roll change times despite investing in operational excellence initiatives. Roll changes, which accounted for 20% of lost production time, continued to exceed the targeted two-minute window, often taking 15 minutes or more. Manual tracking methods failed to capture the root of the issue—until Shoplogix introduced a smart, simple solution.

The Challenge:

• Roll changes were consuming up to 15 minutes, well beyond the two-minute target.
• Manual data collection didn’t capture the true scope of the inefficiencies.
• Despite consulting support, the issue remained unresolved, affecting production goals and leading to costly overtime.

The Solution:

• A simple switch was added to the roll mandrel to track roll change times automatically.
• Real-time alerts were set up to notify the team when the two-minute target was exceeded.
• Data integration into existing systems enabled continuous monitoring and analytics.

The Results:

• Roll change times were reduced to under two minutes consistently.
• 20% of previously lost production time was recovered.
• Operational visibility improved, enabling the team to manage and sustain performance gains.
• Greif was finally able to hold the gains, not just get them.

Key Takeaways for Manufacturers:

• Simple, smart connectivity can uncover and resolve hidden inefficiencies.
• Accurate, real-time data is essential for sustaining improvements.
• Small hardware enhancements, when paired with integrated analytics, can lead to significant operational gains.