CPI Supply is a process improvement company that delivers value-added services to plastic injection and blow molding clients. Their focus on continuous improvement helps identify operational inefficiencies, reduce waste, and optimize packaging and production workflows.

Challenge

CPI Supply’s client was facing frequent downtime on their automated fill line due to poor packaging consistency and flawed design. To improve performance and reduce waste, CPI partnered with BCI to reengineer the packaging system and enhance operational efficiency.

Solution

BCI conducted a full packaging audit and visited the manufacturing site to assess real-time performance issues on the client’s automated line. After identifying the root causes, BCI developed and delivered alternative prototype designs for field testing. These test runs provided tangible data on the performance improvements and validated the design direction.

Results

  • Initial trials reduced client downtime by 40–50%
  • Dramatic improvements in production line flow and reduced waste
  • BCI awarded primary supplier status for corrugated packaging

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