Case Study 1: Modernizing Corrugation Manufacturing through Technology Integration

Client: FlexiPack Corrugators Pvt. Ltd.
Challenge: FlexiPack Corrugators, a medium-sized corrugated packaging manufacturer, faces challenges in maintaining consistent product quality, efficiently managing box variations, and keeping up with production demands due to manual manufacturing processes.
Solution:
Phase 1: Technology Assessment and Planning The 5M Corru consultancy firm conducts a thorough assessment of FlexiPack’s manufacturing processes, identifying pain points and opportunities for improvement. After analyzing the current technology landscape and understanding the client’s objectives, they develop a comprehensive modernization plan.
Phase 2: Automation Implementation

1. Automated Cutting and Folding: To improve efficiency and reduce errors, the consultancy firm recommends the integration of advanced robotic cutting and folding systems. This ensures precise dimensions and shapes for each corrugated box, reducing material wastage.
2. IoT Sensors and Real-time Monitoring: IoT sensors are strategically placed throughout the manufacturing line to monitor key parameters such as humidity, temperature, and machine performance. Real-time data collection and analysis allow for predictive maintenance, minimizing downtime and ensuring consistent quality.
3. Automated Quality Control: Vision-based inspection systems are introduced to identify defects, inconsistencies, and print quality issues in real-time. This guarantees that only high-quality products move through the production line, reducing the need for manual inspections.
4. Customization Software: A user-friendly computer-aided design (CAD) software is implemented to streamline the design process for customized boxes. This empowers clients to easily specify their packaging requirements, leading to faster turnaround times.
   Phase 3: Employee Training and Change Management
   Recognizing that the shift to automation can be challenging for employees, the consultancy firm provides comprehensive training programs to upskill the workforce. They also facilitate change management strategies to ensure a smooth transition and foster a culture of continuous improvement.
   Results:
   • Quality Improvement: The integration of automation and real-time monitoring leads to a significant reduction in manufacturing defects, resulting in a 25% improvement in product quality.
   • Efficiency Boost: The optimized production line increases overall efficiency by 30%, allowing FlexiPack to meet rising demand without expanding their workforce.
   • Box Mixing Made Easy: The CAD software and automation allow for efficient mixing of box sizes, shapes, and designs, meeting the varied demands of clients without compromising on efficiency.
   • Competitive Advantage: FlexiPack gains a competitive edge by offering faster turnaround times, consistent quality, and customized packaging solutions.
   • Employee Satisfaction: Through proper training and change management, employees embrace the new technology, leading to improved job satisfaction and reduced resistance to change.
   By successfully modernizing their manufacturing processes through technology integration and automation, FlexiPack Corrugators Pvt. Ltd. experiences improved product quality, increased efficiency, and a stronger market position.