The challenge
CorrBoard faced numerous challenges upon entering the industry. The complexity of manufacturing corrugated board requires a deep understanding of the systems that underpin the process.
The company's initial struggle was the lack of integration and communication among different Original Equipment Manufacturers (OEMs) involved in the manufacturing process.
Katie Woodward, Head of Operations at CorrBoard, explains: "When I first came into this industry, everyone said that making cardboard is black magic, but when you look into it, it boils down to the processes you have in place. You have the same raw materials going into a machine, and while the machine can have different components, controlling the corrugator is crucial to what comes out the other side.”
One of the first steps towards overcoming these challenges was establishing strong relationships with key OEMs. CorrBoard worked tirelessly to foster collaboration between OEMs, ensuring that issues could be addressed collectively rather than in isolated silos.
Katie adds: "One of the biggest challenges I faced with this role was managing the key OEMs involved in the corrugating hall. These OEMs are all intertwined, so issues in one section can affect the entire corrugator. Initially, we needed stronger relationships with these OEMs and often faced a blame game when problems arose."
Key requirements
Integration and communication to ensure seamless operation and problem-solving.
Process control to ensure consistent product quality.
Seasonal adjustments to maintain consistent product performance.
Sustainability to reduce waste and energy consumption, aligning with CorrBoard's commitment to sustainability.
Employee training and development to foster a culture of continuous improvement and development.
Escada Corrugator Quality and Process Control
Maximize efficiency and maintain process control in the corrugated industry.
The results
Since adopting Escada's solutions, CorrBoard has experienced significant growth and enhanced operational efficiency. The company heavily invested in its workforce, fostering a culture of continuous improvement and development. Low staff turnover rates and extensive training programs contributed to a motivated and skilled workforce capable of driving the company forward.
Katie emphasizes the importance of culture: "Since I started in this role, we have heavily invested in our culture, and it’s been a significant journey. We have a very low staff turnover and focus on training programs and talent development."
CorrBoard's commitment to transparency and customer communication has set it apart in the industry. By clearly presenting its capabilities and maintaining open lines of communication, CorrBoard has built solid and trust-based relationships with its clients.
Katie notes: "We want to work with anyone who wants to work with us. Sustainability, credibility, and communication are incredibly important to us. We may be unusual in the market because we over-communicate, but we believe it's vital for customers to know where their product is and if there are any issues."
The partnership between CorrBoard and Escada has been instrumental in transforming CorrBoard's operations. Through system optimization, sustainability initiatives, and a strong focus on culture and training, CorrBoard has positioned itself as a leader in the corrugated board manufacturing industry.
Katie concludes: "Our relationship with Escada has been crucial over the past few years. People often say it's who you know, not what you know, but in technology, it's a balance of both. The relationship with Escada has taught us a lot about customer service and support, setting us apart from our competitors."
