1. Introduction to BAYONNE PACKAGING, Inc
BAYONNE PACKAGING, Inc is a $43 million printer and paper converter company that produces customized paper-based packaging, for industrial customers, for promotional materials software, luxury beverages, gift good and gift candy. Presently, the business is leaded by Dave Rand and the board of the company is constituted by family members, a local banker and outside counsel.
This company is implemented in the paper packaging industry that was featured by the quickly growth between 1980´s and early 1990´s. Due to organizations that chase the desire to make a greater impact with their promotional materials or moved their promotional budget from print media and broadcast forms to the package itself at the moment of purchase. From the combination of this growth and Bayonne´s aspiration to improve, the company is divided in six major stages: Composition, Sheeting, Printing, Die-Cut, Fold&Glue, Finishing and Shipping dock. In the first one, the goal is to develop the printing and the package design, printing plates are made and die-cutting dies are ordered. Then in the Sheet Department, the paper is sheeted from the roll stock and stacked on skids to be printed. The following one is the Printing department that is where the artwork is printed on 4- and 6-colour presses. In the Die-Cut department, the sheets are printed into “blanks”1. After that, the Fold&Glue department consists in turning the die-cut blanks into the finished product. Here there are two options, if it is a large order it goes to the “Royal/Queen” which is an high speed machine. If it is a low volume order is goes to “Staudes” machines. After this, a selection is made to decide which products are sent to the 3A machines2.
According to the analysis of this company, there are three major problems that have a huge impact on the way the organization functions which are: quality, delivery time and cost of the final