{"id":3608,"date":"2026-03-24T15:18:30","date_gmt":"2026-03-24T14:18:30","guid":{"rendered":"https:\/\/instalin.es\/?p=3608"},"modified":"2026-03-25T13:59:02","modified_gmt":"2026-03-25T12:59:02","slug":"packaging-business-intelligence-lean-manufacturing","status":"publish","type":"post","link":"https:\/\/instalin.es\/en\/packaging-business-intelligence-lean-manufacturing\/","title":{"rendered":"Packaging: Business Intelligence & Lean Manufacturing"},"content":{"rendered":"

Origins: Obstacles<\/strong><\/h2>\n

\"\"

Main wastes identified:<\/strong><\/h2>\n

\"\"

Starting Point of Efficiency<\/strong><\/h2>\n

\"\"

Current status of the changes<\/strong><\/h2>\n

\"\"

Production System created & used<\/strong><\/h2>\n

\"\"

Lean techniques used in the project<\/strong><\/h2>\n

\"\"

Production Systems VS Agile Systems<\/strong><\/h2>\n

\"\"

 <\/p>\n

Production System created<\/strong><\/h2>\n

 <\/p>\n

\"\"

ORGANIZATION FOCUSED ON CONTINUOUS IMPROVEMENT<\/strong><\/h2>\n

 <\/p>\n

\"\"

ORGANIZATION FOCUSED ON CONTINUOUS IMPROVEMENT<\/strong><\/h2>\n

 <\/p>\n

\"\"

Production System created<\/strong><\/h2>\n

CONTROL & KPIS: LEAN-6Sigma REPORTING<\/strong><\/h2>\n

 <\/p>\n

\"\"

Flash results \u2013 visual management<\/strong><\/h2>\n

 <\/p>\n

\"\"

CONTROL & KPIS: LEAN-6Sigma REPORTING<\/strong><\/h2>\n

\"\"

Production System created<\/strong><\/h2>\n

 <\/p>\n

\"\"

5S & ERGONOMICS & CONSUMABLES CONTROL<\/strong><\/h2>\n

BEFORE<\/strong><\/p>\n

\"\"

5S & ERGONOMICS & CONSUMABLES CONTROL<\/strong><\/h2>\n

<\/span>Transformation Methodology<\/strong><\/h2>\n

 <\/p>\n

\"\"

5S & ERGONOMICS & CONSUMABLES CONTROL<\/strong><\/h2>\n

AFTER<\/strong><\/p>\n

 <\/p>\n

\"\"

Production System created<\/strong><\/h2>\n

 <\/p>\n

\"\"

Current focus of work: Creating a production system<\/strong><\/h2>\n

Moving from an organization where we rely on excellent people and mediocre processes to an organization with excellent processes and average people.<\/p>\n

 <\/p>\n

\"\"

Creation of a custom-made process manager<\/strong><\/h2>\n
    \n
  1. Consumables Ordering Processes<\/li>\n
  2. Roller management processes<\/li>\n
  3. Shift change reports<\/li>\n
  4. Staff allocation parts<\/li>\n
  5. Battery leveling control processes<\/li>\n
  6. 5S Checklists \/ Consumables<\/li>\n
  7. Autonomous Maintenance Management Modules<\/li>\n
  8. <\/li>\n<\/ol>\n

    \"\"

    Planning the management tasks for each Lean technique<\/strong><\/h2>\n

    \"\"

    Production System created<\/strong><\/h2>\n

     <\/p>\n

    \"\"

    Planning Management Process Map: VA \/NVA<\/em><\/strong><\/h2>\n

     <\/p>\n

    \"\"

    Stock generator, overproduction, waiting times, general dissatisfaction<\/p>\n

    <\/span>INSTA-PLAN: Pull Flows & Shorter Lead Times<\/em><\/strong><\/h2>\n

     <\/p>\n

    \"\"

    Advantages of Insta-Plan:<\/strong><\/p>\n

      \n
    1. Synchronization of all departments in the same Planning<\/li>\n
    2. Elimination of administrative work<\/li>\n
    3. Evolution of real-time planning<\/li>\n
    4. Reduction of Over-production & Pull Flow throughout the company<\/li>\n
    5. Reduction of Changeover Times & Start-up Losses through a Sequencing Module<\/li>\n
    6. Freeing up resources to perform other tasks \u2013<\/li>\n<\/ol>\n

      <\/span>Insta-Plan Visual Planning Example:<\/em><\/strong>\u00a0Production manager terminal<\/em><\/strong><\/h2>\n

       <\/p>\n

      \"\"

      Terminal Manager of Production:<\/strong><\/p>\n

        \n
      1. Green light system when all raw materials are available within the production unit<\/li>\n
      2. Scheduling algorithm respecting the performance of each machine and the weekly maintenance needs<\/li>\n
      3. Visual alerts in case of delays in Planning \u2013<\/li>\n<\/ol>\n

        Insta-Plan Visual Planning Example:<\/em><\/strong><\/p>\n

        <\/span>Internal provider terminal<\/em><\/strong><\/h2>\n

        \"\"

        Internal Provider Terminal View:<\/strong><\/p>\n

          \n
        1. Visual alert system in case of danger during machine entry time<\/li>\n
        2. Real-time production monitoring \u2013<\/li>\n<\/ol>\n

          <\/span>Comprehensive planning and unique management<\/em><\/strong><\/h2>\n

          The\u00a0Planning management\u00a0<\/strong>It is vital in the industry to avoid:<\/p>\n

            \n
          1. Loss of performance across the entire production system due to lack of materials<\/li>\n
          2. Loss of plant performance due to poor sequencing of manufacturing orders<\/li>\n
          3. Increased waste due to poor sequencing of manufacturing orders<\/li>\n<\/ol>\n

            In addition to these economic impacts, it is obvious that good planning management improves our service quality and competitiveness through the reliability of our delivery times.<\/p>\n

            Planning management in offset printing is often an obstacle course full of low-value-added tasks that saturate various company resources, diverting them from their main functions:<\/p>\n

              \n
            1. Section Chief (15%->50% of time)<\/li>\n
            2. Warehouse (10%-30% of time)<\/li>\n
            3. Plant Coordinator (5->10% of time)<\/li>\n
            4. Support Department: (FTP\/ Inks \/ Formatting Machine \/ Varnish\/etc\u2026) (5%->10% of time)<\/li>\n<\/ol>\n

              <\/span>Graphic Arts Example: Ink codes to reduce changeover times<\/h2>\n

               <\/p>\n

              \"\"

              Production System created<\/strong><\/h2>\n

               <\/p>\n

              \"\"

              Integrate SMED into the culture<\/strong><\/h2>\n

              \"\"

              Identifying Downtime Weight Change Families<\/em><\/strong><\/h2>\n

               <\/p>\n

              \"\"

              Exchange Rate Analysis<\/em><\/strong><\/h2>\n

               <\/p>\n

              \"\"

              Strategy for improving the added value of personnel<\/strong><\/h2>\n

               <\/p>\n

              \"\"

              LIST OF TASKS TO PREPARE<\/strong><\/h2>\n

               <\/p>\n

              \"\"

              Implementation Control of Change Preparation<\/strong><\/h2>\n

               <\/p>\n

              \"\"

              Production System created<\/strong><\/h2>\n

               <\/p>\n

              \"\"

              Integrate Continuous Autonomous Maintenance as a culture<\/strong><\/h2>\n

              \"\"

              Insta-TPM: Importance of Autonomous Maintenance<\/strong><\/h2>\n

               <\/p>\n

              \"\"

              Insta-TPM, a global management tool for Autonomous Maintenance:<\/strong><\/h2>\n

               <\/p>\n

              \"\"

              Continuous Autonomous Maintenance<\/strong><\/h2>\n

               <\/p>\n

              \"\"

              Insta-TPM, an easy and agile tool for selecting and assigning priority autonomous maintenance tasks<\/strong><\/h2>\n

               <\/p>\n

              \"\"

              Production System created<\/strong><\/h2>\n

              \"\"

              The Visual Maintenance Plan<\/strong><\/h2>\n

              \"\"

              We have created this Maintenance Communication tool with the following objectives:<\/strong><\/p>\n

                \n
              1. Have a Visual Maintenance Plan<\/li>\n
              2. Standardize production diagnostics<\/li>\n
              3. Prioritize requests based on their impact on OEE<\/li>\n
              4. To promote efficient collaboration between Maintenance & Production<\/li>\n
              5. Controlling the quality of maintenance service<\/li>\n
              6. Eliminate administrative work and information loss<\/li>\n
              7. Improve Efficiency through Improved Maintenance<\/li>\n<\/ol>\n

                <\/span>Advantages & Functions of the Visual Maintenance Plan<\/strong><\/h2>\n

                 <\/p>\n

                \"\"

                Perfect Maintenance: A Complex & Broad Challenge<\/strong><\/h2>\n

                 <\/p>\n

                \"\"

                Impact Levels of a Maintenance Request<\/strong><\/h2>\n
                \n\n\n\n\n\n\n
                PARAMETERS<\/strong><\/td>\nIMPACT LEVEL 0<\/strong><\/td>\nIMPACT LEVEL 1<\/strong><\/td>\nIMPACT LEVEL 2<\/strong><\/td>\nLEVEL OF IMPACT<\/strong>\u00a03<\/strong><\/td>\n<\/tr>\n
                SPEED<\/strong><\/td>\nIt doesn't influence<\/td>\nMicro-stops with mild repercussions and\u00a0loss of up to 1000 units\/hour<\/strong><\/td>\nMicro-stoppages with notable impact and\u00a0loss of up to 1500 eq.\/hour<\/strong><\/td>\nMicro-stoppages with significant repercussions and\u00a0loss greater than or equal to 1500 ex. \/ hour<\/strong>\u00a0Security Risks<\/td>\n<\/tr>\n
                STRIKES<\/strong>\u00a0(Account<\/em>\u00a0double)<\/em><\/td>\nIt doesn't influence<\/td>\nStoppages with minor repercussions and\/or losses of\u00a0up to 5 minutes per change<\/strong>\u00a0Breakdowns of up to 30 minutes<\/strong><\/td>\nStrikes with significant impact and loss of\u00a0up to 15 minutes per change<\/strong>\u00a0Breakdowns of up to 45 minutes<\/strong><\/td>\nStrikes with significant repercussions and losses\u00a0greater than or equal to<\/strong>\u00a015 minutes per change<\/strong>\u00a0Breakdowns lasting more than 45 minutes<\/strong>\u00a0Security Risks<\/td>\n<\/tr>\n
                DECREASE<\/strong><\/td>\nIt doesn't influence<\/td>\nDisturbances that involve a\u00a0increased shrinkage of up to 5%<\/strong>\u00a0the jobs<\/strong><\/td>\nDisturbances that produce a\u00a0increased shrinkage of up to 10%<\/strong>\u00a0the jobs<\/strong><\/td>\nDisturbances that produce a\u00a0increase above 15% of<\/strong>\u00a0the jobs<\/strong>\u00a0Security Risks<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/figure>\n

                <\/span>Current KBA Applications<\/h2>\n

                 <\/p>\n

                \"\"

                Production System created<\/strong><\/h2>\n

                 <\/p>\n

                \"\"

                AGORA ZONE<\/strong><\/h2>\n

                \"\"

                AGORA ZONE: EFFICIENCY MANAGEMENT<\/strong><\/h2>\n

                <\/span>EXCELLENCE IS IN THE DETAILS<\/em><\/h3>\n

                 <\/p>\n

                \"\"

                 <\/p>\n

                AGORA ZONE: INNOVATION MANAGEMENT<\/strong><\/h2>\n

                <\/span>THERE'S ALWAYS ROOM FOR IMPROVEMENT<\/em><\/h3>\n

                 <\/p>\n

                \"\"

                AGORA ZONE: QUALITY MANAGEMENT<\/strong><\/h2>\n

                <\/span>TODAY'S QUALITY IS TOMORROW'S FUTURE<\/em><\/h3>\n

                \"\"

                \"\"

                Breakdown Tracking & Extended Downtime<\/strong><\/h2>\n

                 <\/p>\n

                \"\"

                RESULTS<\/strong><\/h2>\n

                 <\/p>\n

                \"\"

                What have we achieved?<\/strong><\/h2>\n

                \"\"

                Times of Change: Excellent<\/strong><\/h2>\n

                 <\/p>\n

                \"\"

                Trend Changes 2015 vs 2016<\/strong><\/h2>\n

                 <\/p>\n

                \"\"

                 <\/p>\n

                Evolution<\/strong>\u00a0Decrease<\/h2>\n

                 <\/p>\n

                \"\"

                 <\/p>\n

                Financial Results<\/strong><\/h2>\n

                 <\/p>\n

                \"\"

                Direct evaluation method (Management Controller)<\/strong><\/h2>\n

                \"\"

                INDUSTRIAL POINT OF VIEW
                \nEXTRA HOURS TO SELL\u2026.<\/strong><\/h2>\n

                 <\/p>\n

                \"\"

                INDUSTRIAL POINT OF VIEW
                \nLESS CARDBOARD TO BUY\u2026<\/strong><\/h2>\n

                 <\/p>\n

                \"\"

                ANNUAL INDUSTRIAL REPORT INSTA-LEAN PROJECT
                \nOffset section only<\/strong><\/h2>\n

                 <\/p>\n

                \"\"

                 <\/p>\n

                5-year projection<\/strong><\/h2>\n

                Given the stabilization of results during the last 6 months of the project and that the results of the first 6 months were modest because the project was in the implementation phase, we can estimate that the level of savings in production hours can be maintained without major new efforts in the coming years.<\/p>\n

                This allows us to make the following projection:<\/p>\n

                 <\/p>\n

                \"\"

                \n\n\n\n\n\n
                YEARS<\/strong><\/td>\n1<\/strong><\/td>\n2<\/strong><\/td>\n3<\/strong><\/td>\n4<\/strong><\/td>\n5<\/strong><\/td>\n<\/tr>\n
                Accumulated savings optimistic scenario<\/td>\nxxx K\u20ac<\/td>\nxxx K\u20ac<\/td>\nxxx K\u20ac<\/td>\nx.xxx K\u20ac<\/td>\nx.xxx K\u20ac<\/td>\n<\/tr>\n
                Accumulated savings realistic scenario<\/td>\nxxx K\u20ac<\/td>\nxxx K\u20ac<\/td>\nxxx K\u20ac<\/td>\nxxx K\u20ac<\/td>\nx.xxx K\u20ac<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/figure>\n

                <\/span>PRODUCTION SYSTEM AND SOFTWARE<\/strong><\/h2>\n

                 <\/p>\n

                \"\"

                Or\u00edgenes: Obst\u00e1culos Principales derroches identificados: Punto de Partida de la Eficiencia Estado actual de los Cambios Sistema de Producci\u00f3n creado & empleado Tecnicas Lean utilizadas en el Proyecto Sistema de producci\u00f3n VS Sistemas \u00c1giles   Sistema de Producci\u00f3n creado   ORGANIZACI\u00d3N ENFOCADA A LA MEJORA CONTINUA   ORGANIZACI\u00d3N ENFOCADA A LA MEJORA CONTINUA   Sistema […]<\/p>\n","protected":false},"author":1,"featured_media":3660,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_joinchat":[],"footnotes":""},"categories":[29,79],"tags":[65,64,44],"class_list":["post-3608","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-casos-de-exito","category-productividad","tag-business-intelligence","tag-lean","tag-packaging"],"yoast_head":"\nPackaging: Business Intelligence & Lean Manufacturing - INSTALIN_Results delivered<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/instalin.es\/en\/packaging-business-intelligence-lean-manufacturing\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Packaging: Business Intelligence & Lean Manufacturing - 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