Their customer demanded price reductions so they had to find ways to reduce direct labor costs on their flexible packaging lines.

Work sampling and time studies were performed on three different packing configurations for one specific line. The line is flexible enough to handle a variety of customer packaging requirements, each requiring a different number of people. The three packing configurations observed were all bulk, all in a 72 count box and a combination of a 72 count box, a 6 count carton and bulk. Solutions such as combining jobs, line balancing, simple machine modifications and minor layout changes were developed. The line was previously staffed with anywhere from 8 to 26 people depending on the packaging configuration. With the proposed changes, the staffing was reduced by 2 to 5 people per shift, depending on the packaging configuration.