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.

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

Continuous Improvement (CI) Managers in manufacturing are under constant pressure to optimize performance, reduce costs, and increase throughput. However, many improvement efforts fall short—not because of a lack of effort, but because they focus on the wrong issues, rely on outdated data, or struggle to engage frontline teams.

This playbook outlines how manufacturers can overcome these barriers by using real-time, machine-level insights to identify true root causes, engage operations, and unlock hidden capacity.

Key Takeaways for Manufacturers:

Solve What Really Matters

• Avoid wasting resources on the most visible—but not necessarily the most impactful—problems
• Identify hidden performance drains like speed loss and micro-stoppages
• Prioritize initiatives based on real-time impact, not assumptions

Replace Assumptions with Accurate Data:

• ERP targets and spreadsheets often mask inefficiencies
• Use Top Historical Speed (THS) to uncover true machine potential
• Set smarter standards and detect speed variability early

Engage Operators in the CI Journey

• Lack of frontline engagement can stall even the best strategies
• Empower operators with visual tools, feedback loops, and performance visibility
• Make CI a collaborative effort between leadership and operations

Results You Can Expect:

Reclaim thousands of production hours

• Optimize job speeds and eliminate unnecessary slowdowns
• Increase output—without investing in new equipment
• Build a continuous improvement culture grounded in transparency and accountability

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.