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

Even in facilities with mature continuous improvement (CI) practices, hidden inefficiencies can go undetected, costing time and money. Magna International, a leading global automotive parts manufacturer, faced a puzzling productivity gap despite optimized machine performance and seemingly minimal downtime.

The Challenge:

Magna’s CI team suspected inefficiencies during shift transitions and breaks but lacked the granular data to verify it.

The Solution:

After implementing Shoplogix, detailed loss analytics revealed an unexpected cause: employees waiting to use microwaves during breaks, leading to production delays.

Key Results for Magna:

• 70% reduction in break and shift transition delays
• $520,000 in annual savings
• Enhanced visibility into previously undetectable production losses
• Empowered CI teams to take targeted, data-driven action

Even the most minor inefficiencies can have a major financial impact. With Shoplogix’s real-time analytics, manufacturers can identify hidden production barriers, drive engagement, and turn overlooked issues into significant savings.