Monti Packs a Big Punch with Protein Bar Packaging Overhaul
Situation A manufacturer for protein bar packaging recently moved relocated from a 50,000 square foot operation facility to a new 350,000-square-foot operation facility. This resulted in an assembly line production change where stand-up assembly packaging lines were converted to brand new automated packaging lines. In addition, there was a folding carton redesign where the Straight Tuck End folding cartons were replaced by new Top Kliklok folding cartons. The manufacturer also transitioned to and needed to integrate a new international packaging equipment supplier. Finally, the company needed a new documentation system for more accurate data collection and organization from start to finish.  The manufacturing company hired MetaExpert Kier-Monti, a packaging engineering expert with ample experience to design, measure, analyze, improve, and control the entire packaging process from location A to location B.  Actions Over the course of an 18-month contract, Kier-Monti took the following actions and strategies to evaluate and retool…
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Cross-Functional Disconnect and Order-to-Delivery
Situation MetaExpert Kellen was brought on board to lead a study that focused on lean policy deployment and order-to-delivery (OTD) improvement. According to MetaExpert Kellen, current state analysis determined that there was:  no visual management no leader standard work no cross-functional communication or collaboration no daily metrics tracked or reviewed no daily structured problem solving no cross-functional training or knowledge understanding across departments or production floor processing capabilities In addition, product sales had increased by 35% with no capacity planning or production availability preparation.  Actions MetaExpert Kellen leveraged his expertise in process improvement strategies to get the company back on track. He was able to: achieve lean policy deployment implementation,  complete and develop cross-functional training  Develop and utilize plant capacity model to align sales team with operations available capacity and capabilities develop and improve router instructions for the scheduler to properly utilize plant equipment capabilities and capacity Results/ROI MetaExpert Kellen’s…
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