Consumer Packaged Goods
High-mix lines under cost pressure need to see output against target while the shift is running. If a supervisor first learns that Line 3 fell behind from the end-of-shift report, that hour of output is already gone.
Why CPG operations are hard to run lean
When each line runs a different product at a different rate, comparing them is hard, and harder still when each line's numbers come off its own clipboard.
Frequent changeovers between SKUs use up production time that doesn't show clearly in output numbers. Unless changeovers are timed by product, a slow one just looks like a low-output shift.
When scrap is counted from the bin at the end of the shift and not tied to a line, product or shift, nobody can say which SKU is driving it or where to start.
When the shift's numbers are typed into a spreadsheet from memory after it ends, they arrive late and are often wrong. The next morning's meeting then argues about the figures instead of the causes.
Line performance visible at shift level, in real time
Output, OEE and downtime come from the line automatically as the shift runs, so a supervisor can see mid-morning that a line is behind and do something about it. CPG customers running 10in6 include AprilAire and Energizer.
- OEE and production output by line — actual vs. target, available in real time throughout the shift
- Downtime tracking with reason codes — every stoppage logged with duration, cause, and equipment
- Constraint analysis — identify which station or machine is limiting throughput
- Scrap and rework tracking — by line, product, and shift with trending visibility
- Automated shift reports — emailed to supervisors and managers at shift end, no manual input required
- Multi-line visibility — performance dashboard across all lines simultaneously
OEE in the first 3 months, with downtime cut by two-thirds — plus a 3% weekly output increase within weeks of go-live at a liquid handling products plant
Read the AprilAire case study →Visibility that's there when the shift is happening
Output against target, hour by hour
Output, downtime and OEE update through the shift, so a supervisor can move a person or call maintenance while the shift can still recover.
Shift reports nobody has to type
Shift reports, OEE summaries and downtime analysis are built from the line data. The end of a supervisor's shift goes to the handover instead of assembling numbers for the manager.
Find waste before it becomes habit
Recurring downtime reasons, slow changeovers and scrap trends show up in the weekly numbers before the floor starts treating them as normal.
MES for the lines, DQS for the units they ship
Common questions from consumer goods manufacturers
- How does 10in6 handle high-mix lines and frequent changeovers?
- Changeover and setup time are tracked by product, schedules are delivered digitally to the lines, and OEE and downtime are reported per SKU and per line — so when cost pressure forces a decision, you're working from per-product data instead of a blended average that hides the problem.
- Can shift reports be generated automatically?
- Yes — shift reports are emailed to supervisors and managers at shift end with actual vs. target by line, downtime reasons, and scrap, with no manual compilation. One liquid handling products manufacturer saw a 3% weekly output increase within weeks of go-live, driven largely by making these numbers visible and trusted.
- Does 10in6 support serialized unit traceability for consumer products?
- Yes. AprilAire uses 10in6 scan-to-pack traceability: every component is scanned into the box, bolt count and torque are confirmed per unit, and the shipping label only prints once the unit is complete and final inspection passes. If a customer's unit ever fails in the field, the full birth history is searchable by serial number.
- Do our operators need to be technical to use it?
- No. The Operator Console is a touch-screen interface built for the shop floor — big buttons, configured per line, with downtime, scrap, quality checks, and Andon calls on one screen. We've deployed successfully in plants where operators had no computer background at all.
The problems consumer goods plants bring to us most
An OEE number the floor trusts
Calculate OEE honestly, including mixed products and older machines, and see where the loss is.
Read the answer → CapacityFinding capacity before buying more
Find the real constraint and recover its lost time before adding a shift or a machine.
Read the answer → DowntimeUnplanned downtime nobody can explain
Capture every stop from the machine, code it consistently and work the biggest reasons down.
Read the answer → ReportingShift reports still built in spreadsheets
Replace end-of-shift typing with reports built from the machines, ready for the morning meeting.
Read the answer →After go-live, your team runs it. Operators, downtime and scrap codes, products and targets, shift schedules, checks, alerts, emailed reports and real-time boards are yours to change. New machines, modules and custom reports go through a 10in6 project manager who already knows your plant. How the delivery model works →
See 10in6 applied to your consumer goods operation
Tell us about your lines, your targets and your changeovers. We'll work out which machines to connect first and what the shift would see.