CHICAGO, IL—Welch Packaging—a U.S. corrugated packaging company focused on providing custom packaging solutions to its local customers—has set a new world record for the number of setups in a single eight-hour shift. The Chicago branch of Welch managed 103 order changes in eight hours, each requiring its own setup of the machine. The machine in question is an FFG 8.20 DISCOVERY from Bobst—a flexo folder/gluer, which guarantees the making of high-quality RSC boxes and which is known for its rapid setup time and high productivity.
“We are very proud and very excited to have achieved this world record,” said Doug Poulston, general manager at Welch Chicago. “We believe it is indicative of our culture at Welch—we are committed to our local customers, we have a very ‘can-do’ approach, and we pride ourselves on quick turnarounds. On this particular day, we had large, urgent orders from two of our major customers and we were determined to make it happen for them. With the help of our exceptional flexo folder/gluer and production team, that’s exactly what we did.”
Welch Chicago purchased Bobst’s FFG 8.20 DISCOVERY in the summer of 2017. It was the latest in a line of packaging production machines Welch had purchased from Bobst, the two companies having formed a close partnership.
“We know with Bobst, it is more than just a transactional relationship,” said Dan Kunkes, plant manager at Welch Chicago. “They are invested in our success too; after all, it is good for both parties if we maximize the abilities of their machines. After our FFG 8.20 DISCOVERY was installed, Bobst personnel visited us multiple times to provide the technical coaching needed to ensure best practice and optimal operational techniques. Now our operators are experts on the machine and know how to maximize it, which the world record clearly demonstrates.”
Welch produces corrugated boxes for companies in a wide range of sectors, including food and drink, automotive, chemicals and pharmaceuticals. It particularly focuses on supporting local businesses; as a result, short runs are very common. A machine with a quick setup time and high productivity therefore serves the company very well. The company actually achieved four back-to-back setup world records, including the final run of 103.
“The hidden factor is that the machine has served as an additional catalyst in the already dynamic culture of Welch Packaging,” said Doug. “Our production floor is more competitive from shift to shift than ever before. The energy has been contagious, leading to the four back-to-back world records. Our mantra throughout our organization, instilled in all of us by Scott Welch, is ‘let’s win.’ We are executing on that mantra and ultimately our customers are experiencing the benefits.”
FFG 8.20 DISCOVERY is known for maintaining accuracy and quality at high speed, with fully automated, high-quality folding. What’s more, it is meant to be a user-friendly machine with an intuitive man/machine interface with low maintenance needs.
“Its preventative maintenance program is excellent, letting everyone know when it needs servicing well ahead of time,” said Dan. “The one area where most machines fall down is the machine calibration—that is not the case with FFG 8.20 DISCOVERY. When operators know that the machine is set up accurately and will be accurate all the time, they don’t need to second guess things or make adjustments, and it just makes the whole process much smoother and quicker.”
“We will keep working hard for our customers—whatever they want, we’re going to make it happen for them,” said Doug. “If that results in more records, then fantastic. We were actually very close to the total box production record (which currently stands at 131,518 boxes in a single eight-hour shift), just falling a minute or two short. So that one is in our sights! But ultimately what matters most is achieving what our customers need, and that will continue to be our focus.”
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