Although the age-old adage suggest that good things come to those who wait, people in the box industry know customers do not always buy into this philosophy. When technology and markets improve, so does the expectation for increased box quality and reliable delivery times. It then follows that the plant that can deliver both of these value propositions will get the most business and customer satisfaction. So, when California Box in Southern California purchased an EMBA Ultima FFG and increased productivity by 15% within one year, the desired outcome was achieved. Business increased with the ability to deliver high quality product in shorter time periods.
Although there are many Ultima installations around the world, California Box is one of the first plants to be awarded for its commitment to fast set-up technology with their four EMBA Ultima set while run machines purchased. In total, California Box Group has purchased six EMBA’s since it’s inception in 1984. Now, with EMBA’s newest platform, they are poised to be running four Ultima machines in three of their five plants covering Southern California, Arizona and West Texas. The only company in North America with four EMBA Ultima machines in their arsenal is a testament to the reliability and productivity of these machines.
Increased speed was not the only concern during the purchase process. California Box Group has prioritized short production runs since its founding over 40 years ago. Chris Widera, President, insist on and enforces the standard that speed will not compromise quality. “We always strive for total quality,” said Widera. “We believe in satisfied customers. We are all in the customer service business. Our success is eventually determined by the reaction to our service attitude. Superior responsiveness allows us to be competitive. It also complements the throughput of the EMBA machines.”
Throughout their 40 years in business, Cal Box has moved from serving light industrial end-use markets to the high-tech sector, in which customers are extremely critical of the boxes they receive. Thus, meeting stringent quality and reliability demands became the company’s forte. These quality control requirements set standards for sustainability and waste reduction due to the environmental specs of tough broker and distributor customers. Only boxes that conform to these regulations will ship. The idea of ‘good enough’ does not apply with production off the EMBA’s. EMBA’s full non-crush technology throughout the machine ensures we always produce a better box.
Demand began to outweigh the supply several years back and Cal Box, so adept at producing high quality boxes, needed to change. The plant was running two shifts a day, six days a week. Even with additional hours, the plants could not reach their maximum potential. When Cal Box moved into running E-flute, a more difficult sheet convert, this needed to be addressed. John Widera, the company’s Chairman recognized the problem and took a solutions-oriented approach as written in several of his books. “Unfortunately, a fact of corrugated business is that sheet suppliers are not always able to conform to minimum TAPPI standards as far as flat sheets are concerned. From our industry standpoint, we can either do nothing or we can look for a solution,” Widera said.
The EMBA allows sheets to be controlled from the patent EMBA feeder all the way to the counter ejector with full vacuum transfer. Full vacuum transfer even controls the sheet through the patent Magna Vacuum slot/score section eliminating the need of the slotting heads to pull the sheets though, producing an better box for the customer and causing less issues for the crew. “A smoother production process has allowed line crews to function more efficiently. It made the crews’ job easier, and those are the people you first need to satisfy for increased production,” Widera said.
According to Nick Widera, Vice President of Manufacturing, the purchase of the EMBA’s did more than increase productivity by 15%. It also helped maintain quality production standards with improved print registration. The EMBA is equipped with full servo technology and direct drive print cylinders for improved print capability. With the new feeder technology and elimination of a feed roll a stronger box is also produced. This also allows for lighter weight materials to be utilized without loss of box integrity. Everyone benefits from reduced set-up times: customers, management, production and maintenance crews.
Cal Box has invested in several new machines over the last several years, digital printers and cutting tables, flat bed die-cutters, a 90 x 220″ press, and several specialty gluers. The plants also house rotary die-cutters and in-house ink kitchens directly suited to the need of its high graphic customers. The company also has BHS Corrugated lines to supply flat sheets to their five converting operations.
“Part of our value statement is learn, risk, grow and serve. This means the organization must invest in its people as well. A successful mix comes from integrating the best of both: “great Equipment along with a total productive maintenance program only works if you have the right people as well,” Widera said. “You need to have your team members properly trained and you have to keep the equipment in the best possible condition so crews can meet and adhere to all customer requirements. These are also part of our business model.”
For the California Box Groups five companies, investing in people means creating a cohesive team atmosphere in which every team member can feel confident in having a say in overcoming issues, improving productivity processes and achieving operation excellence. The team concept runs throughout the company and is taught and continually practiced within the Cal Box Group. Management believes continual improvement is everyone’s responsibility and in everyone’s best interest. Each machine center holds interactive team meetings. The plant sponsors machine center and shift bonuses to help keep the crews motivated. Goals are established and when they are met, employees are rewarded and performance is celebrated. For the EMBA crews these goals are consistently being raised as production continues to thrive.
Widera stresses the importance of supporting employees, especially for a job well done. “It’s becoming very difficult to find talent in the industry who have the knowledge of new machine technology and ideas of where a company can grow in the future. Once you find them, they’re truly worth holding onto,” says Chris Widera.
Practicing what it preaches, Cal Box has already demonstrated their commitment to EMBA with the most recent purchase for a machine for its Sante Fe Springs location focusing on the EMBA’s capabilities for customers with high-graphic products requiring problem solving ideas.
The philosophy of continuous learning and adaptation has treated the company well. It seems that good things can come using the on time, with quality and no excuses practices.
