Implementation of an executive system for a print shop
We introduced concrete indicators for 5 shift managers, which shortened order fulfillment time. The percentage of on-time deliveries rose from 78% to 91%.
Drukarnia Offsetowa Echo struggled with chaos in production management. We introduced clear reporting rules that allowed for avoiding downtime on the shop floor.
The challenge
The main problem was the lack of information flow between shifts. Each of the 5 managers kept notes in a different way, which led to errors in orders. During the first 2 weeks of analysis, we noticed that the average waiting time for a decision to start printing was as much as 4.2 hours.
The situation was made worse by downtime resulting from a lack of raw materials, which no one ordered on time. Customers started reporting delays, which in this industry ends in a quick loss of margin. Trust is built on facts, and here system data clearly showed a 12% drop in efficiency compared to the previous year.
Our approach
Civil Strategy focused on simplicity. We abandoned extensive software the staff wasn't ready for and implemented clear task cards for each station. Our team conducted training for 5 managers, establishing that every delay over 30 minutes must be recorded in the register.
We organize the power structure, so we clearly defined responsibility for every batch of materials. We introduced morning briefings lasting a maximum of 15 minutes, during which we discuss only current orders and production bottlenecks.
The solution
We designed a visual system on the production floor. Each machine gained a status board, thanks to which you can immediately see if work is going according to plan. We speak directly about profits, so we invested in a simple SMS notification system for the logistics department regarding low paper stock levels.
Additionally, we implemented a new shift handover protocol. Now the manager finishing work has 20 minutes to complete a report, and the manager starting – 10 minutes to familiarize themselves with priorities. This eliminated unnecessary questions and searching for documentation.
Results
After 6 months of work, Drukarnia Offsetowa Echo achieved operational stability. Thanks to new habits, we reduced the number of erroneous issues and improved the morale of the team, who stopped working in constant stress.
Timeline
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February 2024Audit of information flow on the floor
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March 2024Implementation of a task card system
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April 2024Manager training on reporting
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June 2024Optimization of raw material ordering process
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August 2024Final assessment of system effectiveness
"I was skeptical about changes because the crew has been here for years. It turned out that all it took was to organize one report card for the chaos to disappear. It works, simple as that."