Case Study

Background

One of the world’s largest paper and packaging producers, with plants in Texas, Alabama, and Virginia, sought benchmarking and best practices support across multiple U.S.-based paper mills. At one mill, the company requested a time study to “right size” personnel in the shipping department, with a focus on internalizing inspection and spotting activities within the shipping department.

Solution

Firefly Consulting conducted detailed time studies for each internal and external shipping role, assessing daily, weekly, monthly, and annual demand for activities by position and time of day. Staffing models were developed using trailers, containers, and railcars as the primary workload factors. The study revealed that trailer acceptance was only 80%, compared to an industry benchmark of 90%, highlighting improvement opportunities. Additionally, all inspections were deemed feasible for internal handling, and the spotting driver contract was reduced due to lower weekend demand. Internal roles with low utilization were identified, enabling workforce optimization.

Results

The assessment led to a reduction of 16 full-time equivalent (FTE) positions, representing 20% of the shipping workforce, while maintaining full operational coverage and low overtime levels. These changes resulted in annual savings of over $1M, improved internal processes, and optimized staffing aligned with demand.

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