Challenge
Silgan Plastic Food Containers is a global leader in high-barrier plastic packaging for long shelf-life, ambient, microwaveable and convenience foods, supplying some of the world's most recognisable brands.
Even as an industry leader, documentation ran entirely on paper. That made it hard to find out about or manage issues and incomplete activities, and it left no clear view of who had done what, when, how — or how any of it was affecting operational results. Handing over activities and responsibilities was difficult, particularly when someone was out of the office, and when teams missed critical tasks, acting on it was harder still. Silgan also faces one major audit and several smaller ones every year, and locating the required documentation inside an opaque paper filing system made each of them slow.
Solution
Silgan PFC brought in CAI Parsable, with leadership treating digital transformation as the route to both internal goals — standardising operations — and external ones, keeping pace with competitors, while improving product quality, frontline visibility and employee safety.
Parsable was implemented across quality, production, safety, maintenance and other functional areas, targeting inefficiency in routine processes: quality checks, line profile, preventive maintenance, forklift inspections, perimeter checks and incoming receipt forms. The result was a single source of truth, faster and higher-quality handoffs between departments, digital traceability, and new data points for monitoring equipment trends.
Results
- 20% reduction in audit times
- 10% increase in first-pass yield
- 10% increase in labour efficiency, through quick access to records and documentation when needed
- Thousands of dollars saved in supply chain costs through enhanced accountability measures
- Decreased downtime and improved throughput, by rapidly iterating preventive maintenance routines to catch more errors and remove redundancy
- All information consolidated into a single source of truth
- Faster, higher-quality handoffs of information between departments
- Streamlined reporting through simplified audits
- Digital traceability and new levels of accountability for employees and managers
- Increased collaboration and visibility across safety, quality and production
The Impact
Key Features Used
- CAI Parsable connected worker platform
- Digital quality checks and line profile
- Preventive maintenance routines
- Forklift inspections
- Perimeter checks
- Incoming receipt forms
- Customer-designed dashboards for daily review of critical data points
- Digital traceability and audit documentation retrieval
- Equipment trend monitoring
