Flexible Intermediate Bulk Container (FIBC) industry is currently a sector to watch out for. Due to the increased production of horticulture products and chemicals, the demand for bulk packaging has increased as well. And with increased product demand, organisations are lacking to fulfil the orders on time and in the stipulated budget. In this article, we will discuss about the Transformation in FIBC Industry and few Challenges faced by Industry.
Faber Infinite Consulting has been working extensively in the domain, catering to FIBC, Block Bottom bags, big bags, geo textiles, etc. Faber Infinite team has been instrumental in shaping the continual improvement journeys for more than dozen such industries. Sharing key pointers to be considered for the Operational Transformation in the sector.
Few of the challenges faced by the industry are as follows:
• Overall productivity
As mentioned above, there is increasing demand in the industry, so the organisations need their employees to work harder and deliver more results in the same working hours. This is difficult on the employees’ part and they feel burdened with the increased work. We all know that in cases like these, it is difficult to explain and get the results from the operations department.
In such scenarios team Faber has helped various leading FIBC manufacturing organisations in improving the overall production of the organisation. Team Faber has helped the organizations by eliminating inefficiencies from the processes and by standardizing process parameters. To share the results, we have helped the organisations save manhours by ~25%, improve throughput by ~33% and much more.
• Equipment challenges
Many a times, we face technological challenges such as break down of machines, machine not working at its optimum output and much more. Due to multiple breakdowns, it hinders the employee productivity and overall output.
Hence, to reduce the impact of equipment challenges on the business, team Faber has been helping organizations improve Mean Time Between Failure (MTBF) & reduce Mean Time To Repair (MTTR) by improving Overall Equipment Effectiveness (OEE). It in turn also helps to reduce and eliminate the wastages and improve the loom output. We are glad to share that by implementing these processes at one of the leading FIBC manufacturing organisations, we were able to improve OEE by ~12%, MTBF from 3 hours to 10 hours, reduce wastage from ~7.2% to ~3.3% and ultimately increased the loom output by ~30%.
• Other challenges
Apart from the challenges stated above, there are a few challenges that organisations face similar to the quality of the product, employee skill development, employee training time, raw material wastage and much more.
Team Faber has been helping the organisations optimise all these parameters and is delivering phenomenal results such as;
- 39% increase in production with the same resources
- 38% reduction in manpower cost
- 33% reduction in changeover time
- 31% reduction in material waste
- 27% increase in production using OEE
- 70% elimination of wastage in roll changeover
- 66% reduction in bobbin cutting wastage
Similar results can be delivered in your organizations as well. Contact us at [email protected] to embark on the journey of organizational transformation.
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For further details, read the links below for more information:
Case Studies –
Written & Compiled by Faber Priyal Shah