Challenges Threatened Safety Standards, 15% Revenue Loss, and Industry Reputation
Overview
This multi-million polyester film manufacturer is a critical supplier in the packaging industry. Their operations are essential to maintaining high-quality standards across various industries. However, despite their successful business, they were facing persistent operational challenges that threatened their production capacity and overall efficiency.
Challenge
Several critical issues were severely impacting our clients production, particularly in the packaging, basement, and shipping departments. The primary problem was ongoing staffing shortages, which caused frequent production line shutdowns. Moreover, safety protocols were not being followed, resulting in a rise in workplace incidents. The absence of a 5S program and inadequate training for employees further exacerbated these issues. Temporary employees were not being subjected to proper background checks, creating additional risks. These challenges not only slowed down operations but led to increased downtime, loss of productivity, and potential compliance issues with regulatory bodies.
The shutdowns were a major concern, with key metrics showing a 15% reduction in production output over six months and a 20% increase in near-miss safety incidents.
Our Solution
Understanding the gravity of the situation, Timpl brought in its team of experts to implement a holistic solution that addressed staffing, safety, and operational efficiency. The first step was applying Timpl’s staffing standards to ensure only qualified, vetted candidates were placed into the roles. We conducted a full audit of our client’s staffing needs and rapidly deployed the right talent to stabilize operations.
Next, we introduced and implemented a 5S program, a Japanese workplace organization methodology that emphasizes cleanliness and efficiency. This included rearranging workspaces, reducing clutter, and organizing tools and materials to streamline daily operations. We also launched a comprehensive safety program, ensuring every employee, particularly PIT (Powered Industrial Truck) operators, received thorough safety training.
To address the lack of communication and cohesion among teams, we established daily shift-change meetings, where leads provided updates and discussed daily objectives. Weekly team meetings were also introduced, facilitated via internal TV broadcasts, allowing all staff to remain updated on company goals, safety protocols, and performance metrics.
Our efforts didn’t stop there—Timpl also supported the company’s internal processes by ensuring temporary employees underwent detailed background checks, reducing risks and improving overall workplace safety. We partnered with management to train new hires and offered continuous support to ensure all employees were well-prepared for their roles.
Results
The results were nothing short of transformative. After implementing our staffing and safety programs, our client saw significant improvements:
Zero production shutdowns since our involvement.
A 100% reduction in film misfeeds in the basement, thanks to improved training and processes.
A measurable decrease in workplace safety incidents, with near-miss occurrences dropping by 30% within the first quarter of our intervention.
Productivity increased by 20%, reversing the previous production slowdown.
Beyond the metrics, the overall workplace culture has shifted positively. Employees are more engaged, and safety awareness has skyrocketed, leading to a more harmonious and efficient work environment. Leadership has expressed extreme satisfaction with Timpl’s involvement, noting that we’ve created a more efficient, safer workplace that’s now positioned for sustained growth.
Client Testimonial
“Thanks to Timpl, we’ve experienced a complete turnaround. Their proactive approach to staffing, safety, and operational improvements has been instrumental in getting our production back on track. We appreciate their attention to detail and ability to solve problems where others have failed. We look forward to continuing our partnership with Timpl to ensure our future success.” – Operations Director
Timpl’s superior effort and dedication to providing quality results have allowed our client to overcome its challenges and improve its overall operations, proving that going the extra mile is part of our DNA.