Bayonne Packaging is a specialty packaging converter which is the production of customized, complex-design packaging. They are genuinely used for promotional materials, software, luxury beverages, and gift food and candy. Bayonne Packaging Company which provides all the necessary services from design assistance through final package delivery is located in New Jersey, USA and is worth 43 million dollars.
Currently, the company’s capacity isn’t matching its demand requirements. Heidelberg presses are using 100% capacity (consult Exhibit 1 to get every activity capacity utilization), making Printing activity the bottleneck. Bottleneck slows down the subsequent activities because it can only produce 9.326.913 pieces per month, limiting the inputs available for the Die-Cut center. As the company faces an increasing demand and an expansion of its business the capacity constraint is a challenge. It’s already difficult for Bayonne to fulfill all the orders it receives
Bayonne's sales force worked closely with customers to develop the artwork and package design, culminating in a proof for customer approval. Bayonne then created the printing plates and die, sheeted the paper from roll stock, printed the artwork on 4- and 6-color presses, die-cut the printed sheets into "blanks,"1 and folded and glued the blanks into the final product, which was typically finished at this point and ready to be shipped to the customer or a contents fulfillment house. In some cases Bayonne provided additional finishing work if needed such as attaching string-and-button fasteners, Velcro dots, or other attachments.
Problem Statement (Bayonne Packaging Inc., Performance Problem)
Quality issues come up from the pressure of meeting delivery deadline and insufficient maintenance.
Bayonne Packaging Inc., needs to build up a powerful communication because there is no currently effective one between incorporation and its customers. Without