Coveris, a leading European packaging manufacturer, faced challenges with setup inconsistencies and limited visibility into production issues at their Louth plant. By implementing Shoplogix’s OneSignal, they unlocked powerful real-time insights that quickly drove operational improvements.

Key Challenges:

• Inconsistent setups across 5 printing presses and 17 job changes per day
• Increased scrap, reduced run speeds, and missed production targets
• Lack of visibility into root causes of inefficiencies

The Shoplogix Solution:

• Connected machines in just 1 day (vs. over a month with a competitor)
• Delivered real-time data on key metrics like scrap, setup time, and run speed
• Identified inefficiencies in:
• Mechanical setup
• Registration
• Final adjustments

Results & Business Impact:

• 10% reduction in setup waste, saving £800,000 annually
• 16% increase in run speed, boosting revenue by £340,000
• 9% improvement in OEE, raising plant-wide productivity

Why It Matters for Manufacturers:

This case shows how fast, cost-effective smart connectivity can help manufacturers:

• Gain instant visibility into performance issues
• Standardize processes and reduce variability
• Make data-driven decisions that improve efficiency, reduce waste, and increase profitability

Packaging manufacturers like Genpak often face a familiar set of challenges: late machine starts, inconsistent shift transitions, high rework, and a lack of visibility into what’s actually happening on the floor. Despite having systems in place, Genpak needed a way to surface hidden inefficiencies and act on them in real time.

Through a focused 90-day pilot with Shoplogix, Genpak achieved measurable, high-impact results:

• A +11% increase in OEE
• 8 hours/week saved from roll change optimization
• 6 hours/week recovered by reducing rework on the night shift
• 5 hours/week gained by improving shift handovers

In total, the plant unlocked 19 hours of operational time per week, equivalent to nearly 1,000 hours per year.

This success wasn’t about adding another layer of technology—it was about making performance visible, empowering teams, and building the habits that lead to consistent improvement.

Key Benefits for Manufacturers:

• Real-time visibility into production losses
• Faster changeovers and more efficient shift transitions
• Data-driven accountability between shifts
• A clear path to operational improvement in just 90 days

If your plant is struggling with hidden inefficiencies or underperforming shifts, this case shows what’s possible with the right visibility and a focused action plan.

In today’s fast-paced packaging environment, plant managers face mounting pressure to hit production targets, reduce waste, and improve shift performance — all while managing complex changeovers and tight customer requirements. This guide offers a practical, non-salesy roadmap to help manufacturers uncover and eliminate hidden operational losses in just 90 days.

Based on real-world results from packaging plants using Shoplogix, the guide highlights common challenges — from unplanned downtime and shift creep to inconsistent performance and rework — and outlines a clear 4-step action plan to overcome them. With real-time visibility into your operations, you'll gain actionable insights that lead to measurable improvements.

Key Benefits for Packaging Manufacturers:

• Identify and eliminate up to 19 hours/week of hidden inefficiencies
• Improve OEE with better visibility into downtime, rework, and shift performance
• Standardize changeovers and reduce rework through real-time data
• Empower frontline teams with the right information at the right time
• Achieve tangible results within 90 days

Whether you're battling daily production frustrations or looking to scale best practices, this playbook will help your plant take smarter, faster steps toward high-performance manufacturing.