Without accurate operational and quality data, packaging manufacturers risk over or under-costing their product, inability to redefine processes, and becoming less competitive. Reduce your cost of quality and avoid leaving valuable manufacturing time on the table with visibility across the plant.
Implement meticulous process controls and capture every detail for reduced waste, rework, and recalls.
Bridge knowledge gaps and eliminate guesswork between production stages with real-time insight into any shift, line, or department.
Easily document and adjust to new data standards, customer specifications, and reporting demands.
Improve overall equipment and labor effectiveness by enabling the shop floor to minimize unplanned downtime.
Make the Unbelievable Achievable
Intuitive Process Controls: Implement SPC/SQC tools for operators that inform high quality across all lines and shifts, from raw material processing to final assembly.
Digitize Inspection: Track and trend quality check data at various stages to identify off-spec mixtures and minimize rework, rejections, and recalls.
Live Performance: Monitor and address inefficiencies in real-time with dashboards that inform operators when they’re drifting out of tolerance and immediately surface issues for corrective action.
Reduce waste: Generate tailored reports that pinpoint inefficiencies within quality and production trends to reduce material excess, product overruns, and energy consumption.
Downtime Monitoring: Pinpoint and resolve productivity challenges quickly, optimize capacity utilization, and minimize line disruptions by effectively managing downtime events and unplanned maintenance.
Overall Equipment Effectiveness: Monitor and visualize live performance of throughput, availability, and quality across the production process to accurately assess how efficiently any line or plant is running at any given time.
Streamlined Workflow Management: Create dynamic flows that allow for separate operators to complete checks in order and with minimal interruption. Boost productivity in job shops, batch production, and assembly lines for the day both day and night shifts.
Timeline Updates: Anticipate potential shipment delays and proactively alert customers to make necessary adjustments.
Customer Satisfaction: Consolidate all critical data, enabling a comprehensive view of customer interactions, technical calls, and complaints to organize feedback and pinpoint areas for improvement.
Customer-Centric Reporting: Build stronger relationships through customized dashboards and reports, with insights that provide customers valuable data and analytics.
Compliance Management: Uphold stringent compliance across all plant activities, from raw material receipt to final product shipment. Adhere to each customer’s standards and regulations, such as USDA, FDA, FTC, and more.
Document Visibility and Audit Readiness: Simplify third-party and internal audits with a digital document management system. Alleviate the burden on Quality teams by allowing auditors secure access to specific information and historical records.
Labeling Accuracy: manage data from pre-printed items to nutritional labels so each SKU stays compliant with USDA, FDA, and customer specifications.
EHS and Sanitation: Meet reporting requirements for waste and recycling regulations, and keep sanitation practices in line with the latest standards.
Supplier Management: Organize supplier communication, capture and track critical documentation, and drive corrective actions while complying with ISO, FDA, and other regulatory standards
Risk Management: Oversee the plant’s potential exposure to external risk factors, such as suppliers and ingredients, to improve issue analysis and evaluation of current and future suppliers.
Supplier Traceability: Capture all Quality record data for root cause analysis and integrate with existing tools that track logistics for complete supply chain visibility.
Automated (IoT) Data Capture: Automate the capture of digital data from equipment, ensuring accurate records of changeover times, energy consumption, and quality metrics to ensure every element of any facility is measured and managed.
Traceability: Quickly unify and associate data and identifiers (such as batch/lot info, etc.) with any process documented by your team during the production cycle.
Proactive Maintenance: Monitor equipment in real-time to mitigate unplanned requests and leverage data to support Total Effective Equipment Performance (TEEP).
API Library: Exchange data with ERP and MES solutions through flexible APIs that can be coded to various use cases, and ensure consistent data across the plant.
Inductive Automation (Ignition): Enable machine data captured by Ignition to drive actions within the SafetyChain platform, automating essential plant processes such as quality checks and live OEE monitoring.