Built by Ops Guys, Not Software Salesmen — Discover the Real Flex.
Built by Ops Guys, Not Software Salesmen — Discover the Real Flex.
Built by Ops Guys, Not Software Salesmen — Discover the Real Flex.
Built by Ops Guys, Not Software Salesmen — Discover the Real Flex.
Customer Impact
Customer Impact
Customer Impact
The Numbers Speak for Themselves
Customer Impact
The Numbers Speak for Themselves
Real Customer Impact
Customer Sucesses
Customer Sucesses
Customer Sucesses
Customer Sucesses
Marking Systems, ProAmpac, Spectrum Brands, Energizer, Top 5 U.S. Printer, Latin American package printer
Marking Systems, ProAmpac, Spectrum Brands, Energizer, Top 5 U.S. Printer, Latin American package printer
Marking Systems, ProAmpac, Spectrum Brands, Energizer, Top 5 U.S. Printer, Latin American package printer
Marking Systems, ProAmpac, Spectrum Brands, Energizer, Top 5 U.S. Printer, Latin American package printer
KEY METRICS
KEY METRICS
KEY METRICS
KEY METRICS
162%
162%
162%
productivity increase ($60→$157/hour)
95%
95%
95%
reduction in over-production waste ($150K saved)
15%
15%
15%
changeover reduction
40%
40%
40%
efficiency swing (70%→120%)
60
60
60
day ROI
PRODUCT CAPABILITIES
PRODUCT CAPABILITIES
PRODUCT CAPABILITIES
PRODUCT CAPABILITIES
SQL-to-SQL ERP integration, real-time dashboards, camera integration, automated job stopping, OEE tracking, changeover analysis, visual Andon displays, reason code tracking
SQL-to-SQL ERP integration, real-time dashboards, camera integration, automated job stopping, OEE tracking, changeover analysis, visual Andon displays, reason code tracking
SQL-to-SQL ERP integration, real-time dashboards, camera integration, automated job stopping, OEE tracking, changeover analysis, visual Andon displays, reason code tracking
SQL-to-SQL ERP integration, real-time dashboards, camera integration, automated job stopping, OEE tracking, changeover analysis, visual Andon displays, reason code tracking
Industries: Custom label printing, flexible packaging, consumer products, commercial printing
Industries: Custom label printing, flexible packaging, consumer products, commercial printing
Industries: Custom label printing, flexible packaging, consumer products, commercial printing
Industries: Custom label printing, flexible packaging, consumer products, commercial printing
Case Study: Marking System, Inc.
CLIENT PROFILE
CLIENT PROFILE
CLIENT PROFILE
CLIENT PROFILE
CLIENT PROFILE
Company: Marking Systems
Company: Marking Systems
Company: Marking Systems
Company: Marking Systems
Industry: Custom Label Printing
Industry: Custom Label Printing
Industry: Custom Label Printing
Industry: Custom Label Printing
Size: 73 employees (from 123), 1,000+ jobs/month
Size: 73 employees (from 123), 1,000+ jobs/month
Size: 73 employees (from 123), 1,000+ jobs/month
Size: 73 employees (from 123), 1,000+ jobs/month
Location: Dallas, TX
Location: Dallas, TX
Location: Dallas, TX
Location: Dallas, TX
ENGAGEMENT BASICS
ENGAGEMENT BASICS
ENGAGEMENT BASICS
ENGAGEMENT BASICS
ENGAGEMENT BASICS
Client since: ~2006
Client since: ~2006
Client since: ~2006
Client since: ~2006
Implementation: Phased over multiple years
Implementation: Phased over multiple years
Implementation: Phased over multiple years
Implementation: Phased over multiple years
Key stakeholders: Greg Van Beber (President), Flaviu Borcoman (IT Director)
Key stakeholders: Greg Van Beber (President), Flaviu Borcoman (IT Director)
Key stakeholders: Greg Van Beber (President), Flaviu Borcoman (IT Director)
Key stakeholders: Greg Van Beber (President), Flaviu Borcoman (IT Director)
Products used: Flex Metrics, SQL integration, visual dashboards, camera integration
Products used: Flex Metrics, SQL integration, visual dashboards, camera integration
Products used: Flex Metrics, SQL integration, visual dashboards, camera integration
Products used: Flex Metrics, SQL integration, visual dashboards, camera integration
Problem: Manual clipboard tracking in 40,000 sq ft facility causing unrealistic estimates and wild profit swings.
Problem: Manual clipboard tracking in 40,000 sq ft facility causing unrealistic estimates and wild profit swings.
Problem: Manual clipboard tracking in 40,000 sq ft facility causing unrealistic estimates and wild profit swings.
Problem: Manual clipboard tracking in 40,000 sq ft facility causing unrealistic estimates and wild profit swings.
Previous solution: Employee walking floor with clipboard counting impressions
Previous solution: Employee walking floor with clipboard counting impressions
Previous solution: Employee walking floor with clipboard counting impressions
Previous solution: Employee walking floor with clipboard counting impressions
Marking Systems, Inc:
From Manual Counting
to 120% Efficiency
Marking Systems, custom label manufacturer, 1,000+ monthly jobs Challenge: Manual tracking couldn't scale with 40,000 sq ft facility expansion Solution: Flex Metrics with pioneering SQL-to-SQL integration Results: 162% productivity gain, 50-employee reduction through efficiency, 500 monthly labor hours saved
Marking Systems, custom label manufacturer, 1,000+ monthly jobs Challenge: Manual tracking couldn't scale with 40,000 sq ft facility expansion Solution: Flex Metrics with pioneering SQL-to-SQL integration Results: 162% productivity gain, 50-employee reduction through efficiency, 500 monthly labor hours saved
Marking Systems, custom label manufacturer, 1,000+ monthly jobs Challenge: Manual tracking couldn't scale with 40,000 sq ft facility expansion Solution: Flex Metrics with pioneering SQL-to-SQL integration Results: 162% productivity gain, 50-employee reduction through efficiency, 500 monthly labor hours saved
Marking Systems, custom label manufacturer, 1,000+ monthly jobs Challenge: Manual tracking couldn't scale with 40,000 sq ft facility expansion Solution: Flex Metrics with pioneering SQL-to-SQL integration Results: 162% productivity gain, 50-employee reduction through efficiency, 500 monthly labor hours saved
THE CHALLENGE
THE CHALLENGE
THE CHALLENGE
THE CHALLENGE
Greg Van Beber's 2006 facility expansion should have been triumphant. Instead, the 40,000 square foot space felt unmanageable. Manual clipboard tracking couldn't keep pace. One-minute time studies extrapolated into "unrealistic expectations.
Greg Van Beber's 2006 facility expansion should have been triumphant. Instead, the 40,000 square foot space felt unmanageable. Manual clipboard tracking couldn't keep pace. One-minute time studies extrapolated into "unrealistic expectations.
Greg Van Beber's 2006 facility expansion should have been triumphant. Instead, the 40,000 square foot space felt unmanageable. Manual clipboard tracking couldn't keep pace. One-minute time studies extrapolated into "unrealistic expectations.
Greg Van Beber's 2006 facility expansion should have been triumphant. Instead, the 40,000 square foot space felt unmanageable. Manual clipboard tracking couldn't keep pace. One-minute time studies extrapolated into "unrealistic expectations.
No real-time visibility
70-80% efficiency vs. estimates
Disconnected departments
Lost bids from bad estimates
Operator concerns ignored
The pre-press operator story exemplified the dysfunction—weeks of complaints about an unlevel press dismissed until data proved him right.
The pre-press operator story exemplified the dysfunction—weeks of complaints about an unlevel press dismissed until data proved him right.
The pre-press operator story exemplified the dysfunction—weeks of complaints about an unlevel press dismissed until data proved him right.
The pre-press operator story exemplified the dysfunction—weeks of complaints about an unlevel press dismissed until data proved him right.
THE SOLUTION
THE SOLUTION
THE SOLUTION
THE SOLUTION
IMPLEMENTATION STRATEGY
IMPLEMENTATION STRATEGY
IMPLEMENTATION STRATEGY
IMPLEMENTATION STRATEGY
IMPLEMENTATION STRATEGY
Phase 1: Data validation
Phase 1: Data validation
Phase 1: Data validation
Phase 1: Data validation
Phase 2: Analysis
Phase 2: Analysis
Phase 2: Analysis
Phase 2: Analysis
Phase 3: Optimization
Phase 3: Optimization
Phase 3: Optimization
Phase 3: Optimization
Continuous: "Elephant hunting" (biggest problems first)
Continuous: "Elephant hunting" (biggest problems first)
Continuous: "Elephant hunting" (biggest problems first)
Continuous: "Elephant hunting" (biggest problems first)
KEY FEATURE
KEY FEATURE
KEY FEATURE
KEY FEATURE
KEY FEATURE
Real-time dashboards
Real-time dashboards
Real-time dashboards
Real-time dashboards
Camera integration (click-to-video)
Camera integration (click-to-video)
Camera integration (click-to-video)
Camera integration (click-to-video)
Custom reporting
Custom reporting
Custom reporting
Custom reporting
Performance scorecards
Performance scorecards
Performance scorecards
Performance scorecards
Cultural Commitment: Greg chose losing production hours over missing transformation opportunity. Despite resistance—"My job is to produce, not clock in!"—he mandated participation.
Cultural Commitment: Greg chose losing production hours over missing transformation opportunity. Despite resistance—"My job is to produce, not clock in!"—he mandated participation.
Cultural Commitment: Greg chose losing production hours over missing transformation opportunity. Despite resistance—"My job is to produce, not clock in!"—he mandated participation.
Cultural Commitment: Greg chose losing production hours over missing transformation opportunity. Despite resistance—"My job is to produce, not clock in!"—he mandated participation.
Visual Revolution: Flaviu transformed number streams into 5-second visual insights. "Take out noise, tell the story, find patterns.
Visual Revolution: Flaviu transformed number streams into 5-second visual insights. "Take out noise, tell the story, find patterns.
Visual Revolution: Flaviu transformed number streams into 5-second visual insights. "Take out noise, tell the story, find patterns.
Visual Revolution: Flaviu transformed number streams into 5-second visual insights. "Take out noise, tell the story, find patterns.
What Changed
What Changed
What Changed
What Changed
THE RESULTS
QUANTITATIVE
QUANTITATIVE
QUANTITATIVE
QUANTITATIVE
QUANTITATIVE
$60→$157 per weighted hour (162% increase)
$60→$157 per weighted hour (162% increase)
$60→$157 per weighted hour (162% increase)
$60→$157 per weighted hour (162% increase)
123→73 employees (natural attrition)
123→73 employees (natural attrition)
123→73 employees (natural attrition)
123→73 employees (natural attrition)
500 monthly labor hours saved
500 monthly labor hours saved
500 monthly labor hours saved
500 monthly labor hours saved
70%→120% efficiency
70%→120% efficiency
70%→120% efficiency
70%→120% efficiency
172 monthly setup hours saved
172 monthly setup hours saved
172 monthly setup hours saved
172 monthly setup hours saved
QUANTITATIVE
QUANTITATIVE
QUANTITATIVE
QUANTITATIVE
QUANTITATIVE
20+ year retention through transparency
20+ year retention through transparency
20+ year retention through transparency
20+ year retention through transparency
Hidden champions recognized
Hidden champions recognized
Hidden champions recognized
Hidden champions recognized
Customer trust via facility tours
Customer trust via facility tours
Customer trust via facility tours
Customer trust via facility tours
Tycoon success ($20M revenue, double industry margins)
Tycoon success ($20M revenue, double industry margins)
Tycoon success ($20M revenue, double industry margins)
Tycoon success ($20M revenue, double industry margins)
CLIENT PERSPECTIVE
CLIENT PERSPECTIVE
CLIENT PERSPECTIVE
CLIENT PERSPECTIVE
"Flex transformed our business. Look at the overall picture, not just one thing," says Greg Van Beber.
"Flex transformed our business. Look at the overall picture, not just one thing," says Greg Van Beber.
"Flex transformed our business. Look at the overall picture, not just one thing," says Greg Van Beber.
"Flex transformed our business. Look at the overall picture, not just one thing," says Greg Van Beber.
"You only get out what you put in. Without upper management buy-in, you won't succeed," he emphasizes.
"You only get out what you put in. Without upper management buy-in, you won't succeed," he emphasizes.
"You only get out what you put in. Without upper management buy-in, you won't succeed," he emphasizes.
"You only get out what you put in. Without upper management buy-in, you won't succeed," he emphasizes.
Their transparency philosophy: "What's on production TVs is exactly what we review in meetings. No surprises."
Their transparency philosophy: "What's on production TVs is exactly what we review in meetings. No surprises."
Their transparency philosophy: "What's on production TVs is exactly what we review in meetings. No surprises."
Their transparency philosophy: "What's on production TVs is exactly what we review in meetings. No surprises."
"All good things come from profit—better wages, benefits, equipment. We're not profit-greedy. It's for everybody."
"All good things come from profit—better wages, benefits, equipment. We're not profit-greedy. It's for everybody."
"All good things come from profit—better wages, benefits, equipment. We're not profit-greedy. It's for everybody."
"All good things come from profit—better wages, benefits, equipment. We're not profit-greedy. It's for everybody."
KEY TAKEAWAYS
KEY TAKEAWAYS
KEY TAKEAWAYS
KEY TAKEAWAYS
Executive commitment essential
Culture beats technology—use data to improve, not punish
Visual storytelling transforms understanding
Elephant hunting finds what matters
Transparency builds trust
Marking Systems, Inc.
Case Study Summary
SQL-to-SQL integration capability
SQL-to-SQL integration capability
SQL-to-SQL integration capability
Unlike other solutions that relied on manual exports or flat-file transfers, Flex enabled a direct SQL-to-SQL connection.
Unlike other solutions that relied on manual exports or flat-file transfers, Flex enabled a direct SQL-to-SQL connection.
Unlike other solutions that relied on manual exports or flat-file transfers, Flex enabled a direct SQL-to-SQL connection.
Unlike other solutions that relied on manual exports or flat-file transfers, Flex enabled a direct SQL-to-SQL connection.
Real-time visibility promise
Real-time visibility promise
Real-time visibility promise
Before Flex, leaders were always looking at yesterday’s numbers. Flex offered the ability to monitor machine status, efficiency, and throughput as it happened.
Before Flex, leaders were always looking at yesterday’s numbers. Flex offered the ability to monitor machine status, efficiency, and throughput as it happened.
Before Flex, leaders were always looking at yesterday’s numbers. Flex offered the ability to monitor machine status, efficiency, and throughput as it happened.
Before Flex, leaders were always looking at yesterday’s numbers. Flex offered the ability to monitor machine status, efficiency, and throughput as it happened.
Data to validate operator concerns
Data to validate operator concerns
Data to validate operator concerns
Operators often knew when something was wrong, but their concerns were dismissed as “opinions.
Operators often knew when something was wrong, but their concerns were dismissed as “opinions.
Operators often knew when something was wrong, but their concerns were dismissed as “opinions.
Operators often knew when something was wrong, but their concerns were dismissed as “opinions.
Unite Floor and Leadership
When your shop floor and leadership can finally communicate clearly, operational excellence follows.
Copyright © 2025 Flex-Metrics by Ops Guys. All Rights Reserved
Unite Floor and Leadership
When your shop floor and leadership can finally communicate clearly, operational excellence follows.
Copyright © 2025 Flex-Metrics by Ops Guys. All Rights Reserved
Unite Floor and Leadership
When your shop floor and leadership can finally communicate clearly, operational excellence follows.
Copyright © 2025 Flex-Metrics by Ops Guys. All Rights Reserved
Unite Floor and Leadership
When your shop floor and leadership can finally communicate clearly, operational excellence follows.
Copyright © 2025 Flex-Metrics by Ops Guys. All Rights Reserved
Unite Floor and Leadership
When your shop floor and leadership can finally communicate clearly, operational excellence follows.
Copyright © 2025 Flex-Metrics by Ops Guys. All Rights Reserved