CASE STUDIES

Colonial Printing

Automation brings control and visibility to Colonial’s print and folding carton plant

The Query

Colonial Printing Mailing and Packaging needed a modernized system to keep pace with its growth..

When Dale Ford stepped into his role as the new president of a rapidly expanding print and packaging company, he was thrust into a situation demanding urgent modernization. The business had recently scaled up from a modest 10,000 sq ft warehouse to a sprawling 40,000 sq ft facility and broadened its services to include folding carton production. Confronted with outdated systems, manual processes, and a lack of visibility into job profitability, Ford recognized the pressing need for an advanced ERP/MIS system to streamline operations and support the company’s growth trajectory.

PRODUCTS

Folding carton, digital, wide format,
commercial

MACHINES

40” 6-color Heidelberg press with
in-line AQ coating, Bobst die
cutters, multiple folder/gluers

COMPANY size:

50 + employees

Location:

Huntsville, Alabama, US

The challenge

Colonial struggled with legacy software and a workflow riddled with manual processes..

Colonial Printing faced several challenges that hindered its operational efficiency and growth. The company, expanding rapidly, relied heavily on manual processes like scheduling with Excel spreadsheets. And using an outdated, unsupported MIS system for estimating. “I walked into a plant which had no true MIS system: They had an estimating system, but a lot of time was wasted because it was not set up correctly,” Ford explains.

This lack of a unified system led to significant inefficiencies in managing their increased workflow, particularly with the introduction of new production capabilities such as folding carton. The reliance on manual systems not only slowed down operations but also increased the likelihood of errors, making it difficult for the company to maintain profitability and customer satisfaction. “One of my biggest frustrations was figuring out the WIP.” Ford says. “I was doing all this manually, which took a day and a half at the end of every month just to get a guestimate.”

According to Jeff Collins, VP of Production, “We realized we needed to automate the flow from estimating to production. Every day I would sit in long planning meetings to figure out scheduling…lots of time was wasted because we did not know what was happening on the shop floor.”

“We realized we needed to automate the flow from estimating to production. And that automation would save us a lot of money. It takes out those non-value add activities and tasks and just throws them away!”

The solution

A system that automated the manual touches, provided modern scheduling , giving data visibility and complete control over production.

To address the operational inefficiencies at Colonial Printing, HiFlow Solutions implemented an ERP/MIS system tailored to automate and streamline the company’s outdated processes. This modern solution provided critical real-time data visibility and enhanced control over production workflows.

Jeff Collins, the operations manager, emphasized the transformative impact of HiFlow’s system, noting its unparalleled ability to automate operations and provide comprehensive data insights.

With HiFlow, Collins could instantly plan jobs, receive timely inventory updates, and manage production timelines effectively, significantly improving decision-making and operational efficiency at Colonial Printing. “I can plan a job with the click of a button and know exactly when I can turn something around based on the estimate, and with information from inventory, it alerts me about anything that may be wrong.”

The digital scheduling tool displayed on screens throughout the facility allowed every team member to see their specific tasks and machine assignments, boosting transparency and efficiency. “I get all the data,” Collins says. “HiFlow offers that total picture of the plant in real time with real data and gives us the ability–especially us in operations and manufacturing – of what’s happening on the plant floor at any time. I have all the data i need to assess situations and make decisions. There’s no solution we could find that that does the automation like HiFlow does.”

Collins reflects further: “Having a schedule on a screen that everyone can see – this is my machine, and this is what job i’m running – you can have that high level overview with HiFlow. I think it’s going to have a big impact in our shop and our workflow being able to take all those different variables into account. That’s going to add up and make us more efficient.”

“One of the key things that I’ve learned from this integration is how the HiFlow system really fits our specific needs in packaging. We couldn’t find that in any other solution.”

Takeaways

Automation eliminates touches, reduces time

Collins emphasized the significant benefits of automating the workflow from estimating to production. By implementing automation, Colonial Printing managed to streamline operations and also reduced human error dramatically. Automation minimized the manual input required by operators, enhancing overall efficiency and accuracy in the production process. “A lot of the human error is also taken out. No more 20-30 touch points for an operator just to put the accurate information into that job.”

Control and visibility

Collins highlighted the critical need for automating the workflow from estimating to production as a strategic move to enhance efficiency and cost-effectiveness. This automation was seen as a way to eliminate non-value-adding activities, streamlining operations and significantly reducing wasteful practices. “We realized we needed to automate the flow from estimating to production. And that automation would save us a lot of money. It takes out those non-value added activities and tasks and just throws them away!”

The shift not only promised financial savings but also aimed to improve workflow visibility and control, ensuring that every stage of production was optimized for performance and aligned with the company’s growth objectives. This approach allowed Colonial Printing to focus resources on areas that directly contribute to value creation and customer satisfaction.

Scheduling simplified

Scheduling through HiFlow’s system has significantly benefited Jeff Collins’ workflow at his packaging company. “I now have dynamic scheduling! So, I no longer have to sit in planning meetings for 30 minutes to figure out how to best plan a job to make sure it meets the customer’s expectation,” Collins elaborates.

The system allows for immediate and adaptive scheduling adjustments that take into account multiple operational variables. This capability not only saves time but also enhances efficiency throughout the shop floor by ensuring jobs are planned in the most effective way to meet customer expectations.

“I think it’s going to have a big impact in our shop and our workflow being able to take all those different variables into account. That’s going to add up and make us more efficient.”

The algorithm-based dynamic scheduling can forecast and preempt bottlenecks, optimize machine use, and align production schedules with delivery deadlines, ensuring that the company can meet customer demands more effectively and with reduced operational costs.

Positive implementation experience

“The key to a successful integration of new software is the feeling of not being just a number. The HiFlow team visited our facility, and we were introduced to all the people who would build the system,” Collins continues.

“You know those involved in the project and implementing it by their first names,” says Ford. Collins concurs. “It’s extremely important that you have a team behind the solution that understands your business, understands the pitfalls of integrating something new and transitioning from an old legacy solution to the new solution.

“With HiFlow, the people on the team were absolutely phenomenal in the planning and preparation phase. We always knew where we were at in the process, and we were always kept on task. There’s a lot of requirements that need to happen to integrate a solution like this and they walked us the whole way through.”

Collins reflects on Colonial’s implementation experience. “One of the key things that I’ve learned from this integration is how the HiFlow system really fits our specific needs in packaging. We couldn’t find that in any other solution.”

 

The Benefits of Partnering
with HiFlow Solutions

We implement – fast. The HiFlow system combines MIS and MES software with easy ERP integration.

We fill your ERP gaps. By optimizing ERP systems with MIS and MES features required for packaging and label printing.

We create automated environments. With seamless connections from order intake to shipping and invoicing.

We feed you data. With insights from real time, critical information from your production shop floor, personnel, and equipment.

We let you see. From smart scheduling to nested layouts to workflow diagrams, instantly see where you stand within the job.

Do you have additional questions about implementation? Contact our experts to discover how HiFlow System can help address your company’s challenges.