Faced with the challenges of a changing business landscape and a drive for profitability, many companies have adopted philosophies such as operational excellence without looking at the bigger picture.
Traditional operational excellence has been rooted in the continuous improvement (CI) and waste reduction practices of lean manufacturing, Six Sigma, or world-class manufacturing, which are primarily procedural approaches, according to a recent report from LNS Research. While these methods can prove to be valuable, their success is dependent on a company’s expert knowledge, high degrees of operational discipline, manual execution and long project cycle times. So, in situations where talent turnover, slower results and limited scalability are present, these traditional CI systems can face substantial challenges.
To meet the demands of complexity, speed and sustainability, LNS Research says organizations should embed operational excellence into a robust, adaptable operating model — one that defines how work is done, improved and transformed across the entire enterprise.
Looking back to look forward
Many industrial companies have adopted the latest technology fads in hopes of finding the silver bullet that will align their efforts and produce significant business value, according to the LNS report. But lately, some processors have started taking a back-to-basics approach and are reassessing how they can strategically use new technologies, such as artificial intelligence (AI), rather than simply embracing them and hoping for the best outcome.
These end users are focused on practical considerations, favoring compact machines that fit within existing facilities and systems that reduce operator headcount, according to State of the Industry Report 2025, a new study from PMMI, The Association for Packaging and Processing Technologies. In fact, solutions such as enhanced ergonomics and intuitive human/machine interfaces (HMIs) have become key purchase differentiators, as buyers seek equipment that is easy to operate and maintain, even in environments with high labor turnover and limited technical expertise.
Some machine builders also are moving past the hype of AI and big data, PMMI’s report states, focusing instead on practical applications that solve real problems. Vision systems are a good example. State-of-the-art camera technology and smart software can enable defect detection and activate emergency stops when products fall out of place. Other technologies, such as AI-powered HMIs that translate error codes and guide operators, are gaining interest due to their ability to support less-experienced staff in high-turnover environments and can become an excellent tool to achieve operational excellence.
Predictive maintenance also has the potential to solve manufacturing challenges, according to PMMI’s research, but its acceptance has been lagging among end users wary of its implementation costs and reluctant to abandon preventive maintenance routines. However, some machine builders see progress improvements in predictive systems integrated into HMIs with simple, actionable alerts.
A qualified workforce remains one of the most pressing factors facing processing industries, particularly the shortage of skilled tradespeople, technician burnout and limited internal capacity to scale with customer demand. In response, some original equipment manufacturers (OEMs) are incorporating labor guidance into machinery and creating proposals to help buyers evaluate operational readiness.
Entire free library of solutions
PMMI’s OpX Leadership Network explores common industry challenges and develops work products through special task forces and solutions groups. The entire OpX library of solutions is free for all to use.
Recently, the OpX Leadership Network focused its efforts on bridging the workforce divide: seasoned operators with decades of institutional knowledge are leaving the industry, while a new tech-savvy workforce comes in with a fresh perspective on learning, relevance and impact. This generational shift demands not just replacement but also reinvention of how work is performed.
To aid in this process, the OpX Leadership Network has launched two industry-led solutions: Operator Training Standardization (OTS) and Data Management Standardization (DMS). Built collaboratively by OEMs and consumer product goods (CPG) firms, these work products are designed to close the gap between experience and execution — accelerating onboarding, strengthening data practices and elevating performance across entire operations.
The most compelling solutions for operational excellence and labor challenges can be found at PACK EXPO Las Vegas (Sept. 29–Oct. 1; Las Vegas Convention Center).
In addition to 2,300 exhibits, show attendees should not miss the more than 100 free educational sessions offered, including:
- Innovation Stages: Seminars on breakthrough technologies and best practices.
- Processing Innovation Stage: Sessions on advancements in processing technologies, focused on efficiency and product quality.
- Industry Speaks: Discussions on industry trends, such as remote access, supply chain, augmented reality and operational efficiency.
- Sustainability Central and the Reusable Packaging Learning Center: Presentations centered on reducing carbon footprints, water consumption, waste and plastic usage; boosting recyclability; advancing circularity; and preparing for regulatory compliance
2025 marks 30 years of PACK EXPO Las Vegas — a major milestone for one of North America’s most comprehensive packaging and processing events. The show is expected to attract 35,000 attendees. Attendee registration for PACK EXPO Las Vegas 2025 is now open at packexpolasvegas.com.
