Prime Packaging

Flexible packaging company wants to upgrade, replace legacy systems, and add MES.

Prime Packaging faced significant operational challenges due to outdated and unsupported systems. “We had an older MIS whose supplier had discontinued support some time ago and whose system ran on Windows 7,” explains Kevin Kollman, owner. “We finally decided it was time to find a better solution.” The company struggled with cumbersome reporting that relied on Crystal Reports and a specialized language that few people understood, making data extraction and analysis inefficient and complex.

Additionally, the absence of an inventory system meant that all inventory management was done manually, leading to errors and inefficiencies. The lack of shop floor data collection further compounded these issues, as real-time insights into production were unavailable. “We had no inventory system – that was all manual; nor did we have any shop floor data collection. So it was time to step up a few levels!” says Kollman.

Legacy systems, manual processes and no real-time data was stifling growth and innovation.

Prime Packaging struggled with numerous inefficiencies due to manual processes and a lack of integration. Daily operations involved re-keying data into third-party systems like QuickBooks, which was a significant time drain. The absence of integration between QuickBooks and other systems led to poor communication across departments, creating silos of information.

“Our estimating system didn’t really work for us. We were using convoluted Excel spreadsheets, and the process wasn’t accurate,” explains Kollman. Estimates were not going out quickly; it was a frustrating situation. Without real-time data collection, Prime Packaging had to manually generate reports, which delayed decision-making and reduced operational efficiency. Additionally, machines were not connected to sensors, so real-time data was unavailable, further hindering productivity and process optimization.

“Our inventory system had been a manual one, so a Warehouse Management System (WMS) was definitely on the radar,” Kollman noted. These challenges underscored the urgent need for a comprehensive software solution to streamline operations, enhance data accuracy, and improve overall efficiency.

Prime embraced a significant overhaul of their systems, integrating and optimizing.

Prime Packaging found a comprehensive and customizable solution in HiFlow. “I like the fact that the HiFlow system was very comprehensive, yet I could configure just what I needed for my company. We ended up with most of the modules HiFlow offers, and finally could get all the real-time data and information across my entire operation,” says Kevin Kolman.

The HiFlow system provided Prime Packaging with a range of modules that could be tailored to meet their specific needs. This customization enabled the company to implement the exact tools necessary to improve their operations, ensuring access to real-time data and information across the entire production process. Prime Packaging’s previous manual inventory system was transformed with HiFlow’s WMS.

“With HiFlow, the inventory management and other modules in their WMS offered substantial functionality. And I had access to reports from any of the WMS modules right from HiFlow’s dashboards,” explains Kolman. This upgrade allowed for efficient tracking of raw materials, work in progress, and finished goods, significantly enhancing inventory management.

One of the main challenges Prime Packaging faced was the lack of real-time data access. “It was a bit of a challenge finding the correct hardware to connect our machines to HiFlow’s data collection system. But HiFlow worked with us to make sure that the machine integration went smoothly.” This collaboration ensured that machines were seamlessly integrated with HiFlow’s system, enabling continuous data flow and operational monitoring.

HiFlow’s integration with QuickBooks was straightforward and effective. “Integration with QuickBooks was fast and seamless, with bi-directional communication.” This integration ensured that financial data was always up-to-date and synchronized, facilitating better financial management and reporting.

Lastly, Prime Packaging benefited from HiFlow’s flexible reporting capabilities. They could generate customized reports and access real-time data across the entire operation. “We like the flexibility of the reports we can generate and our ability to have access to real-time data and information across the entire operation.” This continuous monitoring and analysis provided valuable insights, aiding in the optimization of processes.

Data collection ensures a connected environment

“One of our most important goals was to have all our machines, equipment and processes connected. HiFlow integrated with the sensors we installed on our machines and what we got was complete visibility, control and optimization of production and processes across the company.

“Through collecting data from machines and production processes, our production process is optimized using the tools from HiFlow’s Production Planning and Production Preparation modules. My production manager can track the status of each production order and ensure that production stays on schedule.

“The Shop Floor Data Collection provides valuable insights into resource utilization, machine availability, and labor productivity. HiFlow connects all my departments with what’s going on in production—from customer service, who can update the customer, to inventory systems, to purchasing.”

“The new system, because it offers visibility, connectivity and access to real time data for our reports definitely makes us more competitive in our market segment.”

Improved Estimating Capabilities

Estimating had been a major pain point for Prime Packaging, previously managed through cumbersome Excel spreadsheets. “We had been doing estimating with Excel spreadsheets; PSI just was not working. I found HiFlow’s estimating modules easy and fast, and easy to compare estimates to actuals.” HiFlow’s estimating modules streamlined this process, making it faster and more accurate, which in turn improved customer service.

The people factor

“One factor that stood out was the availability of the team at HiFlow. I dealt with the VP of Sales, Jack Lafler, and at every step of the inquiry process he answered all of my questions and offered as many demos as I and my team needed. I was also pleased to have my questions answered by the product developer himself, and the developers who specialized in flexible packaging.

“I was impressed with the fact that everyone on the HiFlow team, from sales to the developers, spoke our language; all of the HIFlow team were familiar with the terminology and processes that I use every day, and we felt quite comfortable that our needs were understood. This is why we chose HiFlow over the other systems we looked at.”

Qualitative improvement of CX

“Our customer service now has the ability to immediately access information when a customer calls for a status update, rather than having them prowl the production floor looking for status. All of our interactions with our customers are recorded and attached to the job ticket – there is one repository for everything related to each job.

“Also, our jobs move through the plant at a quicker pace, thanks to all the automation features HiFlow offers. We can set triggers for automated emails to customers that give them information about production status and shipping. All of these impact the customer experience in a positive way.”

Implementation concerns eased; smooth transition

“We had been using the older system for 15 years, so there was a lot of change for our employees, and the ability to go back to specific training sessions was important for them. As we worked through the new system, our team really began to see the benefits for them, for the company and for the customers. It’s made for a much more cohesive working environment, and I think people are a lot happier. Sometimes you don’t realize how painstaking something is until you begin to pursue a more modern system. Our people are finding even more ways now to use the system to be more efficient.

“HiFlow recorded all of our training sessions, and we have them in a library for future reference, in case someone needs a refresher, or we are onboarding a new employee. Also, because the HiFlow team created a repor with our key employees; they feel like they can reach out to Support and ask any question, or, reach out when problems are small to get them resolved. It makes them more comfortable with the software and being able to resolve any issues as they come up. That’s a big deal.”
“The new system, because it offers visibility, connectivity and access to real time data for our reports definitely makes us more competitive in our market segment.”

Operations streamlined; workflow more visible

“About 80% of my employees use some aspect of HiFlow daily, and they appreciate the customized role- and rule-based dashboards that makes it easy for them to know what they need to get done. “We use most of HiFlow’s modules to optimize the process from the time a new job comes in and throughout our production process. The estimating system we had with our previous system didn’t really work for us. We were using convoluted Excel spreadsheets and the process wasn’t accurate. Now we have a great estimating system, and it’s very easy to compare estimates to actuals so we can continue to fine tune our estimating process. We can also provide very detailed quotes, which we couldn’t really do before.

“When a new job comes in, all the information on the order, including specifications, purchase order numbers, etc., are entered into HiFlow. This is a streamlined and very efficient process for us. We can see all of a job’s specs on one screen. Shop floor workers have much more job information visible to them and we’ve eliminated most of the manual processes we’ve been doing for years. The business intelligence modules collect all the data from our machines and processes, and we can evaluate what’s going on in real time. We use the dashboards daily and it’s significant that they are customizable to whatever process we want to drill down into.”

Straightforward Implementation

“To begin the implementation process, we had a kickoff meeting that presented our team with exact details on the whole process, how the implementation team would be communicating with us and of course the milestones we could expect. “Change is hard. And it takes some time for any hesitation to newness to diminish. We had been using a legacy system for the last 15 years. But I will say that the HiFlow team was hands on from the beginning. We met with the HiFlow team on site, in person during the mid-stage of the implementation, then again at Go Live. This allowed my employees to experience and understand and fully appreciate the nuances of the software.”

Focus on customer during implementation

“I think the in-person experience that occurred about halfway through really gave my people a connection to the process. The HiFlow implementation team was able to take us through our workflow, walk the plant, meet with our team where they work and help with any questions directly at their workstations. It was extremely helpful.

“We started working with HiFlow in January of 2022. It took some time to assess our current situation and build the HiFlow server based on the information we could retrieve from our existing system. By July, we felt comfortable that the system was in pretty good shape, and we ran in side-by-side with our existing system to make sure everything was working and we had all of the data we needed from our old system. In April 2023, we went live with HiFlow and stopped using the old system.

“First, what I appreciated was the patience of implementation team when we needed to schedule around our peak periods and other times when key personnel were extremely busy.

`“I believe the dedication of the HiFlow implementation team to working with our time constraints contributed to the overall success of the project. Additionally, I always felt I was just a few clicks away from communication (on Teams). What helped make the implementation successful, aside from the frequent remote contact, was the in-person visits. I recommend them. “I also appreciated the training materials the project manager, Romek Kowalczyk, produced for us, and the training library of how-to videos. He even provided a manual in Spanish for our Spanish speaking employees.”