Total production increased by
4.1%
Repair expenses decreased by
50%
Operational efficiency rose by
8.5%
Customer complaints dropped by
67%
Waste was reduced by
28%
Production on hold was reduced by
65%
INTRODUCTION
During the first semester of 2025, PET Plastics achieved significant performance improvements in its Closure Division.
Total production increased by 4.1%, and operational efficiency rose by 8.5%. Waste was reduced by 28%, while repair and maintenance expenses decreased by more than 50%. In parallel, customer complaints dropped by 67%, and the volume of production placed on hold was reduced by 65%.
These results reflect a clear shift in operational outcomes and mark an important step toward the division’s long-term performance goals.
FROM LEGACY TO LEADERSHIP
PET Plastics LLC – Molding Division is a leading Puerto Rican manufacturer of preforms and closures for the bottling industry, with a legacy spanning over 45 years. The company was originally founded in 1978 under the name BAC PLAS. In 2008, it became part of the CC1 Companies corporate group, which marked a new chapter of growth and innovation, including a rebranding to PET Plastics.
In 2011, the company relocated its operations to a state-of-the-art facility in Cidra, further strengthening its manufacturing capabilities. Today, PET Plastics operates 24/7, producing over 2.6 billion units annually, and serving some of the world’s largest non-alcoholic beverage brands and their manufacturing plants across the Caribbean.
PET Plastics is certified under world-class standards of quality, safety, and environmental performance, demonstrating its unwavering commitment to excellence, sustainability, and industry leadership.
THE UNDERLYING CONDITIONS LIMITING PERFORMANCE
By 2024, PET Plastics LLC – Molding Division faced significant challenges that threatened its business goals. A key factor was unplanned downtime, which disrupted production schedules and compromised both product quality and customer satisfaction.
Compounding these issues there were considerable shifts in personnel. The organization experienced high employee turnover, and the generation of senior team members—previously responsible for training new hires—was no longer present, creating gaps in knowledge transfer and onboarding.
At the same time, multiple software systems were implemented simultaneously, adding complexity to day-to-day operations and straining the organization’s ability to adapt effectively.
ACTIVATING THE PILLARS OF RELIABILITY
Recognizing the urgency to improve reliability and operational performance, site leadership partnered with Inventio to launch a six-week manufacturing management transformation.
The first two weeks were dedicated to a deep-dive assessment, which included interviews with 20 team members across four departments and five organizational levels, from frontline personnel to site leadership.
Based on the findings, the organization, guided by Inventio Senior Consultants, developed a four-week implementation roadmap focused on strengthening the following key areas:
1. Operational Excellence
2. Human Capital Management
3. Performance Indicators
4. Preventive Maintenance Optimization
5. Root Cause Analysis
6. Capital Projects
7. Planning and Scheduling
8. Operator-Driven Reliability
9. Defect Elimination
10. Asset Condition Monitoring
11. Lubrication
12. Infrared Inspections
By concentrating on these domains, the company aimed to address equipment issues at their root causes and implement reliability routines to ensure long-term system performance—while fostering a culture of collaboration, transparency, alignment, and accountability.
6 WEEK IMPLEMENTATION DRIVES SUSTAINED PERFORMANCE
Over this transformative six-week period, PET Plastics successfully adopted new manufacturing practices, guided by Inventio through a hands-on and collaborative approach.
The team demonstrated strong flexibility and openness to change, actively engaging in the process and integrating new routines into their daily operations.
This commitment resulted in sustained performance improvements and the achievement of new productivity records.
WHAT OUR CUSTOMER SAYS
"What I loved about Inventio was the way they established a comprehensive assessment process to evaluate where we were failing as an operation in terms of reliability. Thanks to this, critical areas for improvement were identified, and then an integral plan was established where key points were addressed, and visibility was given to all stakeholders, always counting on Inventio's support and technology. I would undoubtedly recommend Inventio to all decision-makers in manufacturing plants."
Victor Díaz
Plant Manager
PET - Plastics
Purpose
Drive productivity
and prosperity with data
Contact Us
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Tel: +1 (787) 312-6549
Cidra, Puerto Rico, United States
