Absorbing seasonal peaks without improvising
A packaging area saw its workload double each season. Line-side replenishment was redesigned to keep up with the pace — no improvised stations, no boxes on the floor.
Study a similar needPackaging, strong seasonality
+35%
peak capacity
5 min
to switch from one format to another
−40%
unnecessary movement
Orders of magnitude observed on the project.
The challenge
At every order peak, the team would set up workstations in a hurry on whatever tables were available. Boxes piled up on the floor, components were hard to find and work postures degraded.
In an environment where hygiene is non-negotiable, this improvisation became a real risk — plus it cost time on every format changeover.
Our response
The issue wasn't hand speed but how stations were fed. Our design office therefore reworked the whole internal logistics.
Mobile tubular workstations, easy to move and to clean between runs.
Color-coded kanban bins: anything missing is visible at a glance.
Paced replenishment from stock, so the line-side area is never empty nor cluttered.
Preset configurations per seasonal format, switched in just a few minutes.
Layout co-designed with the operators to keep every motion within reach.
« Every ramp-up used to be a puzzle. Today we change format in minutes, and the station stays clean. »
Other workshops we transformed
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