In an ever-evolving label
scenario, the need to produce more efficiently, reduce wastage, shorten downtime,
reduce interest and financial stress due to big inventories, reducing manpower
and achieving more revenue per asset are necessities that will add to financial
health of companies. To achieve the here mentioned imperatives, many companies
are increasing the use of digital technologies, automation and artificial
intelligence. This not only helps them to be system driven rather than being human
driven but also empowers them to add to their bottom lines with peace of mind.
Chris Ellison the 20th President of leading global label association
FINAT has transformed his company OPM Group, Leeds UK, to be a lean
manufacturing one with increasing use of automation and digital MIS system to
put in place a workflow that performs efficiently and delivering the desired
results. This leaves the management in a comfortable managing environment,
their customers happy and results in better relations with all stakeholders
including suppliers and customers. A walk through the OPM facility is a delight.
There is perfect workflow with no bottle necks or stagnation of materials. A
very neat and clean unit where every process leads to the next with aid of an
IT enabled workflow and automation. The MIS system has been created by
involving the internal team, all suppliers, prepress developers, logistic
partners and customers as well. Generally, printers do not share information
with their vendors, here the vision of the Ellison family has created a system
that makes the unit to work with perfect harmony and the appreciation they get helps
in better relations with their customers.
In most printing companies the
sales force is nowhere in sight and the general perception on the shop floor is
that sales people have all the fun travelling and partying with customers.
Chris’s vision is to inculcate a sense of togetherness and team work in the
entire workforce. Each shift when workers enter the factory, in the first room
they get to see behind a glass wall, is the sales force working hard at their
desks preparing for yet another gruelling day with customers creating a
continuous flow of order. This also instils a sense of bonding as Chris feels
that all the workforce needs to feel committed and create success with the
inspiration, “Together we will”!
Each order that is entered into the system goes through a digital workflow that
is available on screens throughout the company and every department can see the
progress without any hindrance. From costing, quotation, order approval,
pre-press, inventory management, delivering raw materials to presses,
finishing, packaging, despatch and invoicing goes on in clockwork precision.
All staff, vendors, transporters and customers are hooked on to the system for
the information that they are required to access and react to. It is an
information highway created for smooth travel of all orders from initiation to
delivery.
One cannot see any congregation or unnecessary movement of workers in
the factory or over loaded warehouse. A company with 20 million pounds turnover
has just 73 employees. Chris says, “implementation of these system has helped
us achieve a high turnover of 4 million pounds per asset or per Label press” he
further adds that trained and efficient people are scarce to find so they must
invest in an IT department and in training people, which is expensive, but it
is justified for them to be more efficient. Subscribing to principals of Total Quality Management, all products
at OPM are produced to ISO 9001:2015, BRC/IoP Global Standard Food Packaging
standards Grade AA and PS9000:2016. They are printed using low
migration/ Food Grade Inks. Truly, Chris Ellison as industry leader is
setting examples for peers to follow.
Jack Ellison and his three
partners ran a small engineering company building overprinting machines. His 20
years old son Chris wished to have his own business so started importing Dot
Matrix printers from Germany and selling in UK. While in school Chris did not
really excel in academics but was very inquisitive about how things worked,
enjoyed creativity by changing things and wished to do something different and
innovative. After finishing school education, he went on to a technical college to study
engineering. He had two brothers and a sister. Both his brothers died due to
cancer, one passed away at the age of 34 when Chris was just 15 years and the
second at the age of 40 when Chris was 20 years old. These losses left a void in him and he vowed
never to waste a day in his life.
One Christmas a person made him a good offer and Chris sold his Dot Matrix business. Mean while one of the partners in his father’s company died in 1986 and discontent started between the partners creating uncertainty. His mother too was diagnosed with cancer at the age of 64 however she passed away much later at the age of 93, just one day after Chris moved his operations to the present facility. His father Jack Ellison could not take the stress at that time, so Chris first took over his father’s share in the business that his father was in with partners and later, since he had the cash from sale of his own business, he bought over rest of the partners. The company had at that time just installed a small Tackiboy label press. Operating out of 1000 square foot factory, 95% of the business was coming from the label press, machine manufacturing was terminated making them primarily a label manufacturing company.
One Christmas a person made him a good offer and Chris sold his Dot Matrix business. Mean while one of the partners in his father’s company died in 1986 and discontent started between the partners creating uncertainty. His mother too was diagnosed with cancer at the age of 64 however she passed away much later at the age of 93, just one day after Chris moved his operations to the present facility. His father Jack Ellison could not take the stress at that time, so Chris first took over his father’s share in the business that his father was in with partners and later, since he had the cash from sale of his own business, he bought over rest of the partners. The company had at that time just installed a small Tackiboy label press. Operating out of 1000 square foot factory, 95% of the business was coming from the label press, machine manufacturing was terminated making them primarily a label manufacturing company.
The company was renamed OPM Labels
& Packaging group as Chris wished to produce labels and flexible packaging
which till date remains their core business. In 1989 OPM bought their first
flexo press Propheteer the very first one to be sold into UK. By 1999 OPM
flexibles was in place to produce printed films, filmic laminates and sachets.
They had by then acquired 6 Nilpeter label presses. As time went by OPM have upgraded
their machines by replacing the old ones with new machines. This was done to
achieve better efficiency, low wastages and faster production, the number of
presses remain; 6 Nilpeters. A seventh Nilpeter is expected to be installed in
the last quarter of 2018. About waste management Chris Ellison says “OPM take their
environmental responsibility seriously, we are proud to assure our customers
that their label products are being produced with as little impact on the
environment as possible”. They have recently been awarded their Zero Labels 2
Landfill Certification.
OPM is jointly owned by Chris and
his wife Susan Ellison. Susan is active in business, looks after the human
resource functions, Manage and organise implementation of MIS and Automation
systems, Project Managing, R&D alongside with Chris, offers inputs from a
design and repro background, takes initiatives for new developments,
marketing-Communications and strategic planning. She came to the business with reprographic experience having worked with various companies in the field. Their daughter Charlotte
28 and son Arnold 26 are also working in OPM making it a totally family owned
and managed company.
Chris feels it is challenging to
keep pace with your business as it evolves. One must rely on people and
motivate them to grow with your business, the leadership must have the desire,
passion and will to take it further and pass it on to his team. Chris and Susan
also are involved in a lot of charity work investing time and money in cancer
research and aftercare. His elevation in FINAT as president has helped him to
get a broader perspective of international label trade. It has helped his
expand his knowledge through the global networking platform that FINAT offers. He
tries hard to connect with the large spread out membership base and create
value for members.
The above article is exclusively written for Label and Narrow web magazine USA. This may not be reproduced without permission.
Written by Harveer Sahni,
Chairman, Weldon Celloplast Ltd. New Delhi India September 2018
Hi Harveer, nicely penned article, thanks for sharing!
ReplyDeleteIt is a bit frustrating to note how the Label-printers abroad are so profitable, just 6 presses, only 73 employees and yet a Rs. 160 Cr turnover, and no obvious mention of pricing pressures or dwindling gross margins!!
India seems to be the worst place in terms of Brand Owners / the Packaging “Development” heads / FMCG Purchase folks keep pushing down label-prices despite wanting more value-added features, rearing reverse-auctions, and eroding profitability of all our businesses…!!!
Alas…
Regards,
Mahesh