Case Studies / Packaging
Manufacturing · Packaging ~$85M revenue · ~320 employees · 2 plants

Manufacturing Packaging Company

A corrugated packaging and display manufacturer running multiple converting lines across two shifts.

Lead service: Operational analytics + an AI context layer for the plant floor Engagement: 16 weeks

The situation

  • Throughput varied wildly by shift and by line, with no agreed measure of “good.”
  • Changeover and downtime losses stayed invisible until the monthly P&L landed.
  • Machine and MES data existed but nobody could turn it into a daily signal.
  • Scrap and rework ate margin no one could pin to a cause.

What Grounds did

  • Modernized machine, MES, and scrap data into one clean operational record.
  • Built OEE and bottleneck analysis by line, shift, and changeover.
  • Stood up an AI context layer over operations with agentic end-of-shift reporting.
  • Flagged predictive-maintenance and changeover-sequencing opportunities on the constraint line.

Capabilities deployed

Operational data modernization OEE & bottleneck analysis AI context layer Agentic shift reporting Predictive maintenance

Results

+8 pts
OEE on the constraint line
−28%
Changeover time
Daily
Loss visibility (was monthly)
$1.6M
Throughput value recovered / yr

What stays: A live OEE context layer that writes the end-of-shift report itself.

Explore the model

Run your own numbers.

The same kind of live model we build inside the engagement. Move the inputs and watch the outcome change.

Interactive model

OEE & throughput simulator

Make more with the same lines: recover availability and quality losses, and price them in dollars.

How to use: reduce changeover time, unplanned downtime, and scrap, and set contribution per unit. Bars compare each line's baseline OEE (faded) to improved OEE (solid); the constraint line is the one to move first. The recovered dollars update below.
30%
30%
35%
$0.45
Constraint line OEE +8.2 pts · ~70,264 more units/week with the same equipment.
+70,264
Added units / week
$466k
Scrap & rework cost avoided / yr
$1.64M
Annual throughput value recovered

Illustrative example, not a specific client engagement.

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