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Innovating in Recycling and

INDUSTRY

Manufacturing

  
OUR ROLE

Operations

  
CLIENT

CYSA

  

KARTOTEC

KARTOTEC is part of Grupo Yaguarete, a pioneer in Paraguay’s circular economy. With over 40 years of experience, it manufactures high-quality technical papers for the corrugated and gypsum board industries, using state-of-the-art equipment and automated processes. Its production capacity is 70,000 tons per year. The group also includes Yaguarete Reciclaje, Cartones Yaguarete, and Yaguarete Logística, companies dedicated to recycling, manufacturing paper, and logistics, encompassing a comprehensive and sustainable production model.

In 2022, KARTOTEC worked with London Consulting Group to optimize key components of their operations. The project focused on improving productivity and efficiency, as well as implementing management and control models in several areas, such as recycling, production, procurement, and customer service.

2
CHALLENGE

OVERCOMING OBSTACLES: OPTIMIZING PROCESSES IN THE VALUE CHAIN

KARTOTEC's project focused on optimizing the price for raw materials and improving control over the raw materials, increasing production efficiency, streamlining deliveries, and strengthening negotiations with suppliers and cost control tools.

  • Recycling: Optimizing procurement prices and improving control over the raw materials' moisture levels.
  • Production: Increasing production performance (OEE) and reducing unit costs.
  • Sales: Expediting delivery times and ensuring compliance with the customer service commitments.
  • Procurement: Achieving more effective negotiations in the acquisition of supplies.
  • Costing: Developing more accurate and accessible cost control tools.
OBJETIVE

LEADING WITH PRECISION: OBJECTIVES
FOR END-TO-END CONTROL

KARTOTEC, in conjunction with London Consulting Group, defined several key objectives to improve their leaders’ management skills, increase the accuracy of the management indicators, and improve control over the production costs. Furthermore, they focused on optimizing the plant’s OEE, improving the level of customer service and OTIF indicator, and establishing a more efficient and data-driven management model.

  • Develop the leader’s and middle managers’ leadership skills to optimize their managerial performance.
  • Establish more accurate and useful management indicators to improve decision-making.
  • Create a management model based on reliable information and effective action plans.
  • Control and improve the raw materials’ moisture levels to avoid quality problems.
  • Increase the production plants’ OEE.
  • Improve the level of service and OTIF deliveries for local customers.
  • Keep production costs under control and at optimal levels.
IMPLEMENTATION

JOINT STRATEGIES TO BOOST PRODUCTION AND RECYCLING

London Consulting Group worked with KARTOTEC to optimize communication between managers and improve decisions made as a team. They implemented quick hit plans that improved the recycling process, paper and corrugated production, and strengthened the sales department. Through progress meetings, they ensured that all the departments were in sync and that progress was continuously monitored, improving operational efficiency and coordination between key processes.

  • Improving communication between managers and creating discussion spaces for team decision-making.
  • Implementing quick hits plans to optimize recycling and paper production.
  • Developing joint solutions to improve the corrugated production process and the sales department.
  • Organizing progress meetings to ensure the departments’ participation and to monitor progress.
  • Strengthening coordination between interdependent processes to improve operational efficiency.
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RESULTS

TRANSFORMATIONAL IMPACT ON OPERATIONAL EFFICIENCY

Together with London Consulting Group, KARTOTEC increased operational efficiency in several departments, reduced overtime and cost overruns, improved equipment speed, and optimized relations with suppliers. Furthermore, significant improvements were achieved in the level of service and on-time deliveries, strengthening customer service and overall results.

Recycling

50% reduction in production over time. Implementing a supplier service model that ensures the raw materials' quality, delivery frequency, and value.

Kartotec Production:

3% increase in the equipment’s availability, 5% increase in average speed, and an 11% improvement in the OEE indicator. Waste was reduced by 14%.

Carton Production:

6% increase in the equipment’s availability, 4% increase in average speed, and a 30% reduction in overtime.

Planning:

50% reduction in raw material cost overruns and 80% reduction in backorders.

Procurement:

15% reduction in prices paid for inputs.

Sales:

12% decrease in out-of-range orders, 5% increase in the average ticket amount, 60% increase in customer visits, and a 15% improvement in compliance with the customer service protocol.

KARTOTEC was able to optimize production, reduce costs, and improve operational efficiency in several key areas. These results increased the production equipment’s speed, significantly reduced over time, and greatly improved the deliveries’ punctuality, consolidating improvements in overall productivity.

OPTIMIZE YOURP RODUCTION AND RECYCLING PROCESSES

Find out how London Consulting Group can help you transform your operations, improve recycling and production efficiency, and reach new levels of competitiveness.
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