Innovative Solutions for Process, Engineering & Production Improvement

Growing Pains for a packaging maker

Client: A national flexographic printer and converter recognized in the industry for a $20 Million plant upgrade to top-of-the-line equipment by Heliostar, Totani, Lusch, Fuller, Triumph, and Karville.

Problem: After delivery, the equipment stood under-used for more than 6 months. The operators were all 20-year veterans, but their experience and instincts, honed on obsolete machinery, did not serve them with after the upgrade. Raw materials were wasted, gears were stripped, and one operator was injured during what should have been a routine process.

Solution: Sunnyday’s experts understood that all the problems had a root cause: The manufacturer had trained the client on maintenance as part of the installation process, but not on its operation. Sunnyday took a two-fold approach to the solution: