Packing Lean: Contract Packaging Projects Hitting Continuous Improvement Targets

Challenge: A global healthcare company sought to improve packaging and display operations and increase utilization of equipment. The operation was housed in a 140,000 sq.-ft. facility, and suffered from frequent bottlenecks and minimal visibility to productivity reports.

Solution: GENCO established a Lean culture, which provided a basis for eight "˜Lean Focus' categories around which to deploy improvement projects, including Inventory, Waiting, Defects and more. Using a value stream mapping exercise, current flows were scrutinized and dozens of continuous improvement projects were identified and implemented.

Results: The customer experienced immediate returns from many of the continuous improvement projects, and continues to realize $1 million in annual savings. One project transformed productivity tracking. Previously, supervisors walked around to workstations each hour and recorded productivity numbers. Today, managers use a mobile app to access live data from anywhere. The ability to quickly identify and address bottlenecks has increased productivity by 30%.

About the Solution Provider: GENCO is the recognized leader in product lifecycle and reverse logistics solutions designed to maximize value and reduce costs. GENCO operates 140 value-added warehouse locations comprising 35 million square feet and manages $1.5 billion in freight annually throughout North America. For more information, visit



Phone: 800-378-9671