Improve delivery reliability in corrugated packaging plants
Late deliveries in corrugated plants are rarely caused by a lack of capacity.
They are usually caused by the way the factory system operates.
With 25 years in corrugated manufacturing and former MD experience, I help corrugated packaging sites improve delivery performance by identifying and fixing the bottleneck in their operation.
Operational Experience in Corrugated Manufacturing
25 Years in Corrugated Operations
25 years working in corrugated packaging manufacturing, including roles as Operations Director and Managing Director responsible for safety, quality, output and delivery performance.
Improving Factory Performance
Experience improving delivery reliability, throughput, and operational stability in live manufacturing environments.
Hands-On Production Experience
Practical experience with casemaker plants, die-cutting operations and multi-point gluer production.
Sales win clients. Operations lose them
Factory Performance Diagnostic
A one-day on-site review designed to identify the real constraint limiting delivery reliability and factory flow.
During the visit I walk the factory, review production flow, speak with operators, and assess the information and scheduling systems that drive day-to-day decisions.
The outcome is a clear explanation of:
- where the production constraint sits
- why work is building up in the factory
- why deliveries are late
- the practical changes that will improve performance
If no clear improvement opportunity is identified, there is no charge for the visit.
What I help with
Delivery Reliability
- Improving OTIF performance
- Identifying production constraints
- Reducing firefighting and late orders
Factory Flow
- Reducing Work-In-Progress (WIP)
- Improving scheduling and job prioritisation
- Aligning production with demand
Operational Visibility
- Making Production priorities clear
- Improving communication between sales, supply chain and production
- Creating simple operational dashboards
Investment & Process Decisions
- Assessing new machinery or process changes
- Ensuring new equipment supports factory flow
- Operational advice before capital decisions
Why this matters
Late deliveries in corrugated plants are rarely caused by lack of effort.
They are usually caused by the way the factory system operates.
When the real constraint in the system is not properly managed, work builds up across the plant, priorities become unclear, and teams spend their time firefighting.
Improving delivery reliability requires understanding how the whole factory operates — from sales commitments and material availability to production flow and scheduling.
Experience grounded in corrugated operations
I spent 25 years working in corrugated manufacturing, progressing through operational roles to Managing Director.
This experience includes:
• casemaker and die-cut operations
• multi-point gluing lines
• mixed product manufacturing environments
• improving delivery reliability and factory flow
I understand both the shop floor realities and the commercial pressures corrugated plants operate under.
You’ll deal directly with me from the first conversation through to implementation on site.
Real Operational Results
At Lil Packaging, OTIF delivery performance improved from 60% to 98% by aligning the factory around delivery reliability and giving production teams clear visibility of what needed to be produced and when.
Once the right information was visible, sales, supply chain and production began solving problems together instead of reacting to them.
Let’s talk
If your plant is experiencing late deliveries, excessive work in progress, or constant operational firefighting, a fresh perspective can often reveal the real constraint quickly.
If I cannot identify a clear improvement opportunity during the visit, there is no charge.
📞 +44 (0)7734 030517
✉️ barry@barrylillcorrugated.co.uk