Optimizing Tape Usage for a Leading Food Industry Redistributor
Situation
North America’s largest food industry redistributor sought opportunities to improve efficiency and reduce material waste in their packaging operations. As part of a Single Shift Continuous Improvement (SSCI) project, Group O analyzed the performance of a line at their St. Louis, MO, facility over a four-hour period. The primary focus was to evaluate tape usage and identify cost-saving measures without compromising packaging integrity.
Action
Group O introduced a premium case sealing system designed to optimize tape application. The team closely monitored tape consumption and packaging processes, identifying two key areas for improvement:
Minimizing Stub Rolls: By reducing the number and size of partial rolls left unused, Group O helped streamline tape usage.
Right-Sizing Tape Tabs: Adjusting the tape tab lengths to match operational requirements resulted in significant material savings.
Results
Implementing this tape solution led to a 24.2% reduction in overall tape usage on the line:
10.6% reduction from eliminating excess stub rolls
13.6% reduction from optimizing tape tab lengths
Cost Savings & Environmental Impact
The reduction in tape usage translated into lower material costs, improving the redistributor’s bottom line.
Less tape waste contributed to a more sustainable packaging process, reducing excess plastic waste and enhancing the company’s environmental initiatives.
Improved tape efficiency led to fewer roll changes, minimizing downtime and increasing overall productivity.
By optimizing their tape application process, the redistributor achieved a more cost-effective, efficient, and environmentally responsible packaging solution.
