Kapazitätsverluste durch manuelle Freigabeprozesse für Verpackungsdielen

Definition

The packaging design process in Australia typically follows stages including concept development, refinements, dieline creation and finished art, with multiple rounds of client feedback and legal checks.[2] Packaging proofing and approval is recognised as a complex series of processes involving many stakeholders and multiple artwork sources.[6] When these steps are managed via spreadsheets, email threads and static PDFs, each minor structural change to a box or label requires new PDFs, annotations and re‑approvals, which often arrive out of sequence. From a manufacturing perspective, presses and die‑cutters must wait for final, correct dielines before plates and tooling can be made. If approvals are late or incorrect, presses sit idle or must be re‑scheduled, and existing makeready work is wasted. LOGIC: For a mid‑size Australian folding carton plant with, say, 3,000 productive press hours per year, even a modest 5% loss through waiting for approvals, remakes and extra changeovers equates to 150 hours of lost capacity. At an imputed contribution margin of AUD 700–1,000 per press hour, this is AUD 105,000–150,000 of foregone margin annually. Add to this the labour cost of designers and account managers managing multiple rounds of manual updates: assuming one packaging engineer and one account manager each spend 5–10 hours per week on avoidable administrative re‑approval work, that is roughly 500–1,000 hours per year, or AUD 40,000–80,000 in salary cost at typical Australian professional rates, tied up in non‑value‑adding tasks. Together, this yields a conservative LOGIC estimate of AUD 150,000–230,000 per site per year in capacity loss and wasted labour due to inefficient structural design approval and dieline workflows.

Why This Matters

The Pitch: Australian 🇦🇺 packaging manufacturers lose 5–10% of available press capacity each year to delays and rework caused by slow structural design approval and dieline changes. Workflow automation and digital proofing can recover hundreds of press hours annually.

Affected Stakeholders

Production Scheduler, Operations Manager, Structural Designer/Packaging Engineer, Prepress Manager, Sales/Account Manager, Client Brand Manager

Related Business Risks