The issue
Frequent machine stops caused by detection faults were reducing line availability and effective output.

Why it persisted
The stops were treated as technical “noise”. Mechanical alignment and detection phases had never been fully recalibrated together.

On-site intervention
Targeted machine fiabilization: peeling head replacement, mechanical realignment, phase recalibration, fine sensor tuning.

Measured impact
–44 hours of downtime eliminated in 2 months
≈ €110,000 in avoided costs
Annualized potential > €660,000
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Executive takeaway
EBITDA recovered by eliminating root causes — without investing in new equipment.

The issue
Cartons regularly arrived misaligned, causing daily conveyor blockages and repeated line stops.

Why it persisted
The defect had become “normal”. Incremental adjustments never addressed the mechanical reference and detection logic.

On-site intervention
Full mechanical realignment of guides, sensor repositioning, sensitivity adjustment, and speed harmonization.

Measured impact
15 minutes of daily downtime eliminated
≈ €125,000 in losses avoided over 6 months
Issue permanently resolved in 3 days
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Executive takeaway
A normalized defect was quietly destroying EBITDA. Removing it stopped the bleed immediately.

The issue
Multiple small defects generated recurring micro-stops across the line. Individually minor, cumulatively structural.

Why it persisted
Adjustments existed, but knowledge was not documented. Teams reacted instead of securing the fixes.

On-site intervention
Creation of reference settings, diagnostic logic, adjustment guides, and operator training to secure autonomy.

Measured impact
10 minutes of downtime eliminated per day≈ €112,000 in losses avoided over 8 monthsDefects permanently removed
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Executive takeaway
The value was not the adjustment — it was securing the knowledge so the loss never comes back.

The issue
High rejection rates linked to tamper-evidence detection were causing daily product losses.

Why it persisted
Multiple minor setting issues compounded over time. No global reset of the process had been done.

On-site intervention
Full review of detection, guides, speeds, rollers, and reference settings. Process cleaned and standardized.

Measured impact
100 additional units saved per day
≈ €150 recovered per day
≈ €35,000 recovered annually

Executive takeaway
Small percentages hide real money. Stabilizing the process directly improved EBITDA.

The issue
Production performance was limited not by the machine, but by poorly structured non-productive time (breaks, lot changes, cleaning, operator support).

Why it persisted
The losses were known but scattered across daily operations. No coordinated standard existed to reclaim the time.

On-site intervention
Structuring of breaks, workflows, cleaning standards, and operator support. Progressive testing and coordinated deployment.

Measured impact
TRG: 50.3% → 72.5% (+22.2 points)
+3.2 million additional capsules produced
No equipment investment

Executive takeaway
Capacity already paid for was converted into sellable output.

The issue
Batch changeovers relied on improvisation. Tasks were unclear, sequencing was inefficient, and performance depended on individuals.

Why it persisted
No standardized workflow or role-based support existed. Each changeover was reinvented.

On-site intervention
Full changeover mapping and role-based checklists. Field testing across teams to ensure reproducibility.

Measured impact
Changeover time reduced by 3.5 hours per batch
+658 production hours freed per year
≈ €1,023,000 in additional annual revenue

Executive takeaway
Time previously lost between batches became sellable capacity.

The issue
Quality defects forced the line to operate below nominal speed to remain compliant.

Why it persisted
Lowering speed was the only known way to secure quality. Root causes linking mechanics and process parameters were not identified.

On-site intervention
Root cause analysis across forming, sealing, guides, and process settings. Corrective adjustments secured and documented.

Measured impact
Cadence: 100 → 120 blisters/min
+1,200 blisters/hour
+€8,400 revenue per hour of production

Executive takeaway
Quality issues were masking unused capacity already paid for.

The issue
Carton preparation required two operators for nearly a full day every cycle, despite an existing machine.

Why it persisted
The machine had been idle for months. No one knew how to adjust or operate it correctly.

On-site intervention
Machine recommissioning, full adjustment, documentation, and operator training to secure autonomy.

Measured impact
1 production day freed every 6 days
≈ 39 additional production days per year
No equipment investment

Executive takeaway
Idle assets were turned back into productive capacity.

The issue
The integration of new childproof caps was considered incompatible with the existing line. A new machine was estimated between €400k and €600k.

Why it persisted
Early trials showed torque defects, feeding instability, and tamper-evidence failures. Without a structured diagnosis, the line was judged unfit.

On-site intervention
Full capability diagnosis: real-condition trials, torque analysis, dimensional checks, interaction analysis between caps, feeding system, and tightening heads.

Measured impact
Existing line confirmed viable
€400k–€600k machine investment avoided
Decision secured with technical evidence

Executive takeaway
The issue was not the machine — it was the lack of method.

The issue
Random contamination events led to a €500k customer order being blocked until a reliable mitigation solution could be deployed.

Why it persisted
No existing solution met process, HSE, and ergonomic constraints. The issue required a bespoke design, not an adjustment.

On-site intervention
Functional analysis and custom system design: glove disinfection box with operator detection, controlled cycle, mechanical locking, and integrated HMI.

Measured impact
€22,795 invested
€500,000 order immediately unblocked
Business continuity restored

Executive takeaway
The value was not the equipment — it was restoring revenue flow.

The issue
A strategic customer contract depended on validating a new process. After three months, no functional prototype existed.

Why it persisted
The project required cross-disciplinary expertise (process, mechanics, automation). Efforts remained fragmented.

On-site intervention
End-to-end prototype design: process definition, system architecture, component integration, tuning, and validation.

Measured impact
Functional prototype delivered in 1 month
Process validated
Multi-million € contract signed

Executive takeaway
A €25k prototype unlocked a contract worth orders of magnitude more.

The issue
Spare parts inventory tied up significant cash without guaranteeing equipment availability.

Why it persisted
Lack of criticality and obsolescence analysis led to defensive accumulation rather than economic arbitration.

On-site intervention
10-month structured project: criticality analysis, obsolescence mapping, standardization, and risk-based stock strategy.

Measured impact
€75k–€225k annual gains targeted
Cash released progressively
Industrial risk maintained under control

Executive takeaway
CAPEX and cash exposure were reduced without increasing operational risk.

The issue
Sporadic contamination detected at the customer level led to a €500k order being frozen pending a reliable corrective solution.

Why it persisted
No off-the-shelf solution met quality, HSE, process, and ergonomics constraints simultaneously.

On-site intervention
Design and deployment of a custom glove decontamination system: operator detection, controlled disinfection cycle, mechanical interlock, and integrated HMI.

Measured impact
€22,795 invested
€500,000 order released
Revenue flow restored immediately

Executive takeaway
A targeted intervention restored business continuity where no market solution existed.

The issue
A strategic customer required validation of a new process before signing a long-term contract. Internal development had failed to deliver a usable prototype.

Why it persisted
The problem spanned process, mechanics, automation, and safety. Without system-level ownership, progress remained fragmented.

On-site intervention
End-to-end process prototype design: functional analysis, system architecture, component integration, tuning, and industrial validation.

Measured impact
Functional prototype delivered in 1 month
Process validated
Multi-million € contract signed

Executive takeaway
Without validation, there is no sale. Execution unlocked the deal.

The issue
Misaligned cartons caused daily conveyor blockages, impacting output and delivery reliability.

Why it persisted
The defect had become operationally “accepted”. Temporary fixes replaced root correction.

On-site intervention
Mechanical realignment, sensor repositioning, detection logic correction, and flow stabilization.

Measured impact
15 minutes of downtime eliminated per day
≈ €125,000 losses avoided over 6 months
Issue permanently resolved in 3 days

Executive takeaway
What was considered operational noise was in fact a business risk.

The issue
Random blister integrity defects led to full batch rechecks and occasional destruction, generating recurring financial losses.

Why it persisted
The defect was intermittent and hard to reproduce. Without structured root cause analysis, it remained unresolved.

On-site intervention
Comprehensive root cause analysis (mechanical interactions, process parameters), corrective actions, and knowledge capitalization.

Measured impact
€90k losses observed over 2 months
Up to €540k annual losses avoided
Defect eliminated at the source

Executive takeaway
Stopping one random defect prevented a six-figure annual loss trajectory.