Hub Labels, a Hagerstown, MD-based label converter, has not shied away from experimenting with new technologies and strategies to boost productivity. Thomas Dahbura, president, has actively employed Lean Manufacturing, and his forward-thinking has seen the company place an emphasis on sustainability, safety and community. These measures have been a boon during the COVID-19 pandemic.

Part of Hub Labels’ commitment to Lean Manufacturing requires internal audits that target areas for improvement. One such area included diecutting.

Hub Labels embarked on a year-long project that focused on die strikes. The converter worked diligently with suppliers and customers, all while analyzing its processes to see where the company could increase efficiency.

Hub Labels turned to Kocher + Beck to assist with this project. “We decided to ask Kocher + Beck to come in and look at our processes, identifying the issues with what we were using at the time and make some suggestions for us,” states Jesse Hood, quality and continuous improvement director at Hub Labels. “Our partnership began when we decided to conduct that additional research.”

“We identified some processes and procedures maybe Hub could be doing better, some diecutting 101 principles that still apply today,” explains Bryan Kiesinger, regional sales manager at Kocher + Beck. “This is what we try to do for our customers, where we identify problems and review what they’re doing – both in their hardware and their practices. There was some troubleshooting, some 1-on-1 evaluation with the press operators and the quality control manager, and Hub Labels embraced those ideas and thoughts.”

Kocher + Beck observed a breakdown of magnetic cylinders, which was able to be rectified in a productive and timely manner. The supplier recommended best practices such as care, handling, lubrication and more. Kocher + Beck’s die technology has helped with Hub Labels’ MPS flexo press, as well as its Gallus Labelfire digital hybrid press.

“We’re mainly using their magnetic dies for our hybrid press,” explains Nink Myers, purchasing manager at Hub Labels. “They have a really good program tailored to us, and the technology works really well. We’ve utilized some special coatings to help when we’re cutting through a difficult adhesive or an abrasive material – or we’re just trying to generate longevity for the dies.”

The partnership went beyond diecutting, too. Kocher + Beck reviewed several cleaning and maintenance techniques for Hub Labels’ magnetic cylinders and dies, as well as the storage of the dies.

“We have definitely seen increased efficiency on throughput by using their dies,” says Hood. “They allow us to run faster and cleaner, and the labels aren’t being pulled, so we’re not getting any hard die strikes like we used to. We’re able to run at higher speeds without getting harder impressions on the die.”

Supplier partnerships have played a key role in helping Hub Labels navigate the COVID-19 pandemic. Kocher + Beck bought into the Maryland-based printer’s PDCA (Plan, Do, Check, Act) culture, and that responsiveness has contributed to Hub Labels’ success in 2020.

“Customers are very receptive to our feedback. We’re seeing machines that are wider and faster, and with that the basics of rotary diecutting can sometimes get overlooked,” notes Kiesinger. “You may have embellishments between colors, foils and hot stamping, and all that’s great, but if you aren’t aware of the diecutting procedures, all that effort up front could be wasted.”

Customer service, especially where travel is limited during times of social distancing, becomes ever more critical.

“The biggest benefit from Kocher + Beck was their customer service,” says Hood. “They’ve been willing to bend over backwards for us. If something doesn’t work, we send it to them and they analyze it. They’ve been ready and willing to help us out whenever we’ve had questions for them. The whole printing industry in general has stepped up and tried to be very transparent during the pandemic. This industry is built on partnerships, but it’s also one big family there to help each other out.”

By improving its processes, Hub Labels has seen its efficiency soar during the pandemic. According to Myers, the company has maintained a 98% on-time delivery rate despite dealing with a large percentage of the staff working remotely.

“I don’t think we have had a choice to not be focused on Lean and improving our efficiency,” explains Hood. “We’re actually blessed that we’ve seen a significant increase in sales and we’re producing more now with the same amount of people than we were before. Lean Manufacturing isn’t just something we do, it’s part of who we are – and that’s not just operations but marketing, purchasing, sales and everybody in the entire facility.”