Process Modelling (BPM)
for Manufacture of corrugated paper and paperboard and of containers of paper and paperboard (ISIC 1702)
Given the high fixed costs of manufacturing assets and the logistical complexity of corrugated products, process precision is critical for maintaining profitability.
Strategic Overview
Process Modelling is the backbone of operational excellence in the paper and board conversion sector, where minor process variations can lead to significant yield losses. By mapping the 'order-to-delivery' lifecycle, manufacturers can identify bottlenecks in production changeovers and logistical touchpoints that currently drive up the cost of delivering bulky, low-density products.
Effective BPM strategies focus on reducing 'Transition Friction'—the time lost between converting different box styles or sizes. Streamlining these workflows not only improves asset utilization but also provides the structured data necessary to support long-term investment in automation and digital transformation.
3 strategic insights for this industry
Optimizing Production Line Changeovers
Using SMED (Single-Minute Exchange of Die) methodologies supported by process maps to reduce downtime between different box specifications.
Reducing Volumetric Warehousing Burden
Modeling the flow of finished goods to identify opportunities for 'just-in-time' shipping, given the high storage cost of corrugated containers.
Prioritized actions for this industry
Map and formalize end-to-end production workflows.
Identifies hidden sources of yield discrepancy and production waste.
Implement lean-based inventory flow analysis.
Reduces the volume of 'shipping air' by aligning production batches with actual logistics capacity.
From quick wins to long-term transformation
- Value stream mapping for bottleneck identification
- Standardizing shift handover procedures
- Implementing automated workflow management software
- Integrating raw material hedging into production scheduling
- Full digital twin simulation of manufacturing plant
- Complete automated circular economy loop integration
- Creating static models that aren't updated
- Failing to account for human performance variability
Measuring strategic progress
| Metric | Description | Target Benchmark |
|---|---|---|
| Yield Per Ton | Total usable product output relative to raw board input | >98% |
| Setup/Changeover Time | Time elapsed to switch machine settings for new orders | <15 minutes |
Other strategy analyses for Manufacture of corrugated paper and paperboard and of containers of paper and paperboard
Also see: Process Modelling (BPM) Framework