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Mobilising for Waste Reduction for one of the world’s largest producers of multi-layered packaging bags

Client situation & approach

Our client is one of the world’s largest producers of multi-layered packaging bags. The major part of the company’s cost is made up of raw material costs and a target had been set to reduce waste by 30 %. A data collection system to identify defect modes was implemented which was followed by restoring basic conditions (cleaning, inspection, lubrication and tagging), identifying root causes to defects and counter measures to these. To withhold the gains and create lasting results new routines were set in place.

Results

  • 55 % waste reduction
  • 250K EUR of annual savings
  • 29 collaborators trained in the new standards
  • Improved teamwork between production and maintenance employees
  • Establishment of machine care by production personnel