Packaging specialist, WestRock, has revealed the significant productivity and efficiency gains achieved after investing in a BOBST training programme.
Operators within the die-cutting department at WestRock’s Dublin site, undertook training over a period of 12 months as WestRock sought to upskill its workforce and ensure performance targets were accomplished.
Following the training process, make-readies have reduced by an average of 16 minutes and downtime by 15%. At the same time, sheets per man hour (SPMH) have increased by more than 30%.
The site in Dublin specialises in manufacturing complex packaging for the pharmaceutical and chemicals sectors, requiring exacting precision and accuracy. With four BOBST die-cutters on site, Cut & Crease Manager, Chris Richardson, was keen to ensure operators were achieving optimum performance from the machines.
“Twelve months ago, while we knew we had a great team, we realised that we didn’t have a huge amount of experience working across all shifts and there was a need for upskilling,” said Chris. “The work we were taking on was becoming more complex. It had become clear that we needed to improve department performance and create a knowledge base to ensure we could continue to deliver the high standards our customers expected.
“The make-ready improvement has had the biggest impact for customers and since the training began we have seen a significant reduction, around 50%, in customer complaints,” Chris added. “The training from BOBST has re-energised us and empowered operators to make better decisions and resolve problems themselves. Ultimately, the team understands the capabilities of the machines better.
“In addition, more senior members of staff have been freed up to focus on other roles and responsibilities. For example, the training has provided us with the right techniques for zonal patching - the most complex of tooling – and is now carried out by trainees without a problem.”
BOBST Product Specialist, Tim Lane, said: “The benefits that WestRock has seen demonstrate why an investment in training can really pay off. We work with our customers closely to ensure our machines are performing optimally, and as with Chris and his team, it shows that it isn’t always necessary to invest in new machinery to achieve greater productivity and efficiency.”
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