Customer Success / Packaging Manufacturing

Standardizing Maintenance Operations for a Leading Packaging Manufacturer

headshots (26) Bri Dascher
Marketing Director - Astra Canyon Group

Introduction

A leading North American packaging manufacturer partnered with Astra Canyon to modernize maintenance operations and improve inventory visibility across multiple production facilities.

Operating with separate sites, disconnected maintenance processes, and inconsistent inventory practices, the organization needed a more structured foundation to support operational efficiency, data integrity, and long-term growth.

Rather than replacing every existing system, the customer selected Astra Canyon and IFS Cloud to strengthen maintenance, inventory, and operational workflows while integrating with its existing Acumatica financial environment.

Challenge

Consolidating operations across multiple facilities.

Prior to implementation, two major facilities operated in separate environments with limited standardization between sites.

To support future growth, leadership set out to consolidate operations into a single environment while improving process discipline across sites.

Duplicate Part Numbering

Duplicate and inconsistent inventory part numbering created challenges across facilities.

Limited Inventory Visibility

Teams had limited visibility into obsolete or underutilized inventory.

Site-Specific Processes

Site-specific processes created operational inconsistency between locations.

Manual Workarounds

Manual workarounds reduced data integrity and limited planning across locations.

Turning Point

Building one connected environment for maintenance and inventory operations.

Rather than replacing every existing system, the customer selected Astra Canyon and IFS Cloud to strengthen maintenance, inventory, and operational workflows while integrating with its existing Acumatica financial environment.

The focus was to create a structured foundation that could improve process discipline, support replenishment and maintenance planning, and scale with additional facilities over time.

Astra Canyon’s Approach

Designed around plant maintenance and inventory management.

Drawing on deep manufacturing and supply chain expertise, Astra Canyon designed and deployed an IFS Cloud solution aligned to the realities of plant maintenance and inventory management.

A phased rollout began with the Arkansas facility, followed by Green Bay headquarters, allowing each site to transition successfully while minimizing disruption to daily operations.

01 – Site Consolidation

Consolidated two major production sites into one connected environment.

02 – Financial Integration

Integrated operational transactions with Acumatica for financial reporting.

03 – Inventory Standardization

Improved part number governance and reduced duplicate inventory records.

04 – Visibility Enhancements

Added enhanced reporting, lobbies, and quick reports to improve operational visibility.

05 – Process Improvements

Improved replenishment planning, maintenance execution, and inventory obsolescence management.

Results & Business Impact

A more structured operational foundation across maintenance and inventory processes.

Following go-live, the organization established a more structured operational foundation across maintenance and inventory processes.

Today, the manufacturer is operating on a more connected platform that supports stronger inventory discipline, operational visibility, and long-term standardization across plant operations.

Business outcomes included:

Reduced Creation of Duplicate Inventory Parts
Improved governance helped reduce duplicate inventory part creation.

Improved Maintenance Demand Visibility
Teams gained better visibility into maintenance demand and replenishment planning.

Greater Site Consistency
Previously disconnected sites gained more consistent operational processes.

More Data Captured in the System
More operational data is now captured within the system rather than spreadsheets.

Scalable Platform for Additional Facilities
The platform is positioned to support additional facilities over time.