Case Study

The Folding Carton Company

The Folding Carton Company lacked visibility into operations and assets. They were unable to identify challenges in real time and struggled to adapt to changes in schedules and products, unable to manage rapid changeovers to support manufacturing.

Seeing Challenges as Opportunities

The Folding Carton Company lacked visibility into operations and assets. They were unable to identify challenges in real time and struggled to adapt to changes in schedules and products, unable to manage rapid changeovers to support manufacturing.

Unable to Identify Challenges in Real-Time

Resulting in overall equipment effectiveness (OEE) losses and poor capacity planning.

Low Levels of Productivity

Excessive and manual data entry by equipment operators reduced employee productivity.

Limited Visibility of Operations

Reducing ability to respond quickly to challenges and identify opportunities for improvement.

How O3ai Enabled Smarter Manufacturing

We deployed several systems to provide accurate status of ongoing manufacturing operations, monitor and control asset use, integrate existing systems and provide real-time operational intelligence.

O3ai KPI Management

Allow creation of key performance indicators (KPIs) from vision to results to provide accurate status of ongoing manufacturing operations.

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O3ai Performance

A scorecard and action tracker to provide real time operational intelligence with end-to-end traceability and origin.

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O3ai Loss Analysis

To evaluate effectiveness vs performance and improve planning and forecast inventory.

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O3ai Impact

The Folding Carton Company were able to exceed their targets and improve their performance and key parameters, most notably:

11.1%
Overall Equipment Efficiency (OEE) Increase
11%
Overall Equipment Efficiency (OEE) Increase
10%
Lowered Costs, Increasing Savings
12%
Reduction in Unplanned Downtime
80%
Reduction in Customer Complaints