Comprehensive Analysis Reveals Vital Operational Inefficiencies

The Challenge

Pregis utilized its consultative approach and comprehensive analysis to evaluate the company’s existing paper void fill solution. That evaluation uncovered some vital operational inefficiencies.

Packers were walking, turning, and twisting to find the correct box size (boxes had been placed in multiple areas around the station). Since paper void fill machines were constantly jamming and going down, the fan-folded paper was frequently removed from the machine and placed on the pack table. This problem carried over to the “print and apply” area. There, the packer was pulling the paper from the back of the void fill machine because of the jamming. This meant the worker was repeatedly turning around, pulling, and tearing, causing physical strain, and slowing down the pack process.

The paper void was being filled into boxes inconsistently, too. Many were underfilled causing the top of the box to cave in. The problem was compounded when the boxes were then dropped into a gaylord – which damaged the bottom of the gaylord itself.

In summary, there was a significant amount of unnecessary movement and touches throughout the workflow, creating a need for immediate change.

Solution

After thorough evaluation, Pregis was able to recommend a strategic multi-material approach to resolve their operational challenges. Pregis started with a trial to demo the two alternative solutions it felt would improve workflows significantly:

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