Case Study: Mid-Sized Flexible Packaging Company achieves 5-day lead-time reduction and $76K annual profit gain with WorkClout

Mid-Sized Flexible Packaging Company - Customer Case Study

Mid-Sized Flexible Packaging Company (50–70 employees, serving 1,000+ clients) struggled with paper and Excel-based production management that caused handwritten job specs, poor visibility into set-up/run times, frequent schedule changes, and quality reworks. Using baseline data from 66 jobs, the company experienced 24% of runs with delays (average 15 minutes), average actual lead times of 17 days versus estimated 14 (a 3‑day slip), and an estimated annual loss of about $81,852. To address this, they evaluated and adopted WorkClout’s advanced production scheduler (APS) and manufacturing execution software (MES).

WorkClout implemented visual job management, a production schedule, and an operator portal to digitize job specs and capture run times, pauses and defects. After one month and 57 jobs, delays fell to 9% with average delay time down to 5 minutes, over‑run time dropped to about 5 minutes, and average actual lead time improved to 10 days (roughly 4 days ahead of estimate). The Mid-Sized Flexible Packaging Company saved over 290 hours in a month, reduced clarification time to under an hour, and increased profit margin by more than $76,464 annually thanks to the visibility and accountability provided by WorkClout.