Driving Efficiency and Reliability: MHIA’s Production Improvement Program (PIP) Empowers Box Makers for Long-Term Success

Driving Efficiency and Reliability: MHIA’s Production Improvement Program (PIP) Empowers Box Makers for Long-Term Success

By Jon Rhoades, Machinery Continuous Improvement Specialist, MHIA

Every box maker knows the pressure of keeping production moving in an environment where every second counts. Operators are being asked to do more with less, maintenance teams are stretched thin, and new hires often lack the hands-on experience needed to hit the ground running. The result? Increased downtime, inconsistent machine performance, and inefficiencies that quietly compound over time.

Addressing these challenges requires more than quick fixes—it takes a long-term commitment to efficiency, reliability, and continuous improvement. That’s the goal of Mitsubishi Heavy Industries America’s (MHIA) Production Improvement Program (PIP), a partnership-driven approach designed to minimize waste, strengthen operations, and help EVOL machines reach–and maintain–their full potential.

Understanding the Interconnected Challenges Impacting Efficiency

Across the industry, familiar challenges continue to disrupt operations. Labor shortages, high turnover rates, and a shrinking pool of skilled operators are not just isolated problems. They contribute to a loss of critical operational knowledge. This gap in expertise can lead to the improper use of consumable materials, as well as failing to identify issues during routine inspection, driving up costs and introducing uncertainty into inventory management processes.

In an already strained supply chain, this unpredictability compounds the difficulty of maintaining consistent production levels. Mechanical failures and unplanned downtime further complicate matters, often discouraging the next generation of workers from seeing manufacturing as the viable, rewarding career path it can be.

For companies navigating these challenges, the key isn’t just fixing problems as they arise—it’s putting systems in place to prevent them from happening in the first place.

The Production Improvement Program (PIP): A Partnership Beyond Installation

The PIP extends the traditional OEM relationship beyond machine sales and installation, fostering a collaborative partnership aimed at addressing both immediate issues and the underlying factors that contribute to inefficiency and downtime.

The PIP is structured around continuous improvement principles, drawing on lean methodologies to help identify and eliminate waste in real time. Regular bi-weekly visits from MHIA specialists allow for a thorough evaluation of EVOL performance, maintenance practices, and team dynamics on the shop floor. By observing production processes firsthand, it becomes possible to uncover inefficiencies that might otherwise go unnoticed—whether related to time management, material waste, or workforce utilization.

How PIP Helps Box Makers Take Back Control

In addition to technical evaluations, the program places a strong emphasis on training and knowledge transfer. The goal is to help foster a culture of continuous learning and accountability within each facility, empowering teams to take ownership of process improvements and operational excellence.

Every two weeks, an MHIA specialist visits the plant to observe how the EVOL is running, how teams are interacting, and how maintenance is being performed. Rather than just troubleshooting issues, these visits focus on identifying patterns and systemic inefficiencies that could lead to future problems.

Key areas of focus include:

• • Preventive maintenance oversight – Ensuring maintenance tasks are performed correctly, setting a higher standard for reliability.
• • Machine health assessments – Identifying wear patterns and adjusting procedures to extend equipment life and prevent premature failures.
• • Root cause analysis – Helping teams understand not just what went wrong, but why, so the same issues don’t repeat.
• • Inventory control and machine readiness – Implementing tools such as the PIP card, modeled after Kanban inventory principles, to manage consumables more effectively.

Hands-On Training that Bridges the Skills Gap

In manufacturing, the most effective training happens on the floor, not in a classroom. PIP integrates hands-on instruction into its bi-weekly visits, complementing existing onboarding and training programs. This real-time guidance accelerates skill development for both new and experienced employees.

A key goal of this training is to begin the development of a Lean Champion—an internal expert on the preventative maintenance process, who can answer technical questions and guide other employees after completion of the program. This ensures that the lessons learned through the PIP become embedded in the company’s culture, supporting long-term growth and operational success.

Laying the Groundwork for What’s Next

The results speak for themselves. In as little as two months, facilities participating in the PIP have experienced significant reductions in downtime, improvements in production consistency, and measurable gains in efficiency. Beyond the immediate outcomes, the long-term value of the program lies in the mindset shift it promotes—encouraging continuous improvement and establishing new standards of operational excellence across teams.

The development of this program has been a learning experience in itself, revealing the depth and complexity of the challenges faced by the corrugated industry. More importantly, it has reinforced the belief that genuine partnership goes far beyond a successful installation. True success is built on ongoing support, shared knowledge, and a mutual commitment for long-term growth.