“Innovation beyond the box” is not just a company slogan -- it’s a way of doing business at Charlotte, NC-based Ferguson Supply and Box. With offices and manufacturing operations fittingly located on Quality Drive, Ferguson manufactures and distributes custom and stock corrugated boxes, containers, displays, bags, packaging supplies, foam products, as well as graphic art and design services. With the company’s in-house structure and graphic design team, Ferguson can take a packaging concept from an idea to the retail shelf or into the customers’ hands.
Previously, facilities were divided between two locations totaling approximately 212,000 sq ft. After rethinking processes, organizational methods, and material flow, the company elected to consolidate into one 185,000 sq ft modern facility and implement a “core” operation philosophy. With a growing business and a 27,000 sq ft reduction in total building space, achieving maximum efficiency and organization was essential.
Doing More with Less
Wildeck® material handling solutions provided the necessary components to facilitate the reduction in square footage. More importantly, by strategically locating the mezzanine, a core area for supplies was established close to the manufacturing area.
“Wildeck products add space,” says plant superintendent Terry Pridgen. With Ferguson’s focus on maximizing organization and shifting all operations to one smaller facility, the added space was integral to its material flow.
“The core location of the mezzanine maximizes our efficiency and keeps everything within easy reach,” continues Pridgen. “The easy access allows our operators to quickly switch over jobs while protecting and moving printing plates and cutting dies.”
The added space and efficiency provided by the Wildeck® mezzanine and VRC have provided numerous operational benefits, according to Pridgen.
Tooling storage for the converting machines, printing plates, and dies. These delicate items damage easily and are costly to replace. The mezzanine level protects and stores while the VRC easily transports material to the manufacturing level.- Space optimization. The goal of manufacturing is to keep overhead costs low and maximize profitability. Economically, it is more advantageous to utilize existing overhead space than to increase floor space. Mezzanines also qualify for accelerated capital equipment depreciation compared to the longer terms associated with permanent building improvements.
- Central core location. In keeping with the organization’s philosophy, the improvements have kept necessary materials and components close to the manufacturing area, thereby maximizing production efficiency.
- Time savings. Ferguson prides itself on organization, which greatly reduces the amount of time on each job. The new process is one that anyone could learn with only one hour of training. Now, they do not have to rely on someone’s memory to locate specific materials.
- Aesthetic appeal of the plant. This often-overlooked benefit of Wildeck’s mezzanines and lifts is a huge advantage to Ferguson Box. The company frequently invites its “A-list” clientele to tour the facility, and first impressions matter. The tour showcases the facility, which creates trusting relationships and increases business. An organized and uncluttered feel to the operations and facility convinces guests to trust Ferguson with their work. A smooth-running and organized operation helps to showcase Ferguson’s quality and production efficiency.
Organizing for Success
Terry Pridgen and Gene Massey, plant manager, are dedicated to organizing the plant -- not just to improve operations, but also to present the company’s full ability. The Wildeck® mezzanine and material lift contribute to the success of Ferguson’s operation in several ways.
- Safe storage. The mezzanine stores several key production items, including thousands of cutting dies. They tell the machines where, when, and how the boxes need to be cut and perforated. Delicate printing plates are also stored on the mezzanine. These two items are critical yet easily damaged. With some 4,000 of them to keep safe at any time, Pridgen has plans to relocate to a new tool storage area to consolidate and maximize inventory space.
- Easy access. The VRC material lift operates frequently every day. Tooling is stored up on the mezzanine and when the tooling technician pulls items, they are brought down on the material lift. Some box cutting dies can weigh thousands of pounds, so employees use a special cart to transport them onto the lift and to the machine.
- Under-mezzanine space is also maximized to the fullest. Several defined areas contribute to the centralized “core” operation philosophy. By focusing on the different aspects of certain areas, it has dramatically increased the efficiency of the maintenance shop, ink kitchen, and fulfillment area / pack out.
Ferguson Box’s unique ink station allows the company to make its own ink. By having the ink on location, they are able to fill customer orders faster and reduce ink inventory.
“The location of the mezzanine factored into the location of the ink in our operation,” Pridgen explains. “With the ink isolated and organized, it is easy to determine the inventory, control costs, and analyze the amount used on each job.”
Pridgen is extremely pleased with the combination Wildeck® mezzanine and VRC lift installed in Ferguson’s facility.
“The mezzanine and lift have provided our new facility with the space and efficiency we need to accomplish our goals,” says Pridgen. “We are able to have our dies and materials readily available for use on our equipment. As a result, we are able to maximize our efficiency in an organized fashion, and that greatly adds to our bottom line.”