Case Study: Corrugated Packaging – Recycling
Challenge
Our client is one of the world’s largest paper and packaging companies, and a leader in sustainable, fiber-based packaging solutions. With over 300 production facilities worldwide, the company strives to utilize science and technology to drive innovation in packaging.
Before Augmentir, this company’s recycling operations lost precious time to sluggish, manual processes for activities such as simple daily inspection signoffs. They had no insight into completed inspections, no method to see details across multiple sites, and no programmatical way to report, track, or escalate issues. Additionally, they needed a way to standardize inspections, implement accountability, and record images for documentation.
“We struggled with manual processes for simple sign off of daily inspections and no visibility to completed inspections, and were looking for a solution that would help us digitize and standardize on these processes to improve accountability, traceability, and data reporting.”
Director, Recycling Operations
Solution
The company selected Augmentir as the solution to help them digitize, standardize, and optimize their recycling operations. The company utilized Augmentir’s digital workflow tools to digitize its processes for plant inspections, facility checks, safety checklists, and auditing processes. The built-in data collection capabilities allowed the company the eliminate manual data capture and inspection recordings and provided enhanced documentation for OEM and warranty communications.
Primary Use Cases and Impact Areas
Leader Standard Work
- Digitized paper-based work procedures and SOPs
- Digitized Gemba walks
- Improved team communication
- Performance management monitoring
- Progress tracking, identify areas for improvement through data-driven insights
HSE (Health, Safety, and Environment)
- Safety Audits & Rounds
- Safety Checklist for handling hazardous materials
- Safety guarding & LOTO
- Emission monitoring & observations
- 5S
- Near miss reporting
Floor Inspections
- Standardized guided workflows, competency training, best practices, and execution
- Embedded alerts & help
- Priority check reminders of high-failure components
- Task instructions
- Visual Material and Production Quality Audit / Inspections
Workforce Development
- Standardized and improved training procedures
- Reduced new hire onboarding time by 72%
- Identified upskilling and reskilling needs based on AI-based insights from Augmentir
- Positive impact on continuous improvement efforts
Operations
- Operator Rounds & Inspections (Extruder, Pulp Washer, and other machines)
- Line Changeover
- Facility inspection (motor, wastewater, HVAC, etc.)
- Machine Operation Management
- Shift Handoff
Reporting
- Improved compliance, visibility & reporting
- Enabled supervisors to identify non-conformance activities in timely manner
- Enabled tracking recurring deviations to identify maintenance and process opportunities, avoiding costly shutdowns through enhanced maintenance
Results
By implementing Augmentir’s AI-based connected worker solution, the company digitized manual processes such as inspection signoffs, eliminated manual document scanning and storage, added accountability processes across all locations, and enabled visibility and dynamic access to job data and work being done.
Through insights made possible by Augmentir’s AI-driven operational insights, the company was able to adapt and enhance operations, standardize inspection training, and enforce proper reporting and documentation including media capture to improve reporting and compliance.
“With Augmentir, we were able to quickly digitize many of our paper-based and manual operational procesess, which has helped reduce waste and improve productivity – making a significant impact on improving our sustainability goals.”
Director, Recycling Operations