30
Countries
TPM Implementation Saves €1M Across 30 Teams in Global Packaging
A leading global packaging manufacturer needed to reduce waste, minimize productivity losses, and lower conversion costs across a complex, multinational network. Together with EFESO, the organization deployed a TPM-based operating model and established scalable systems for continuous improvement.
Packaging
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Our Client
A world-leading packaging manufacturer headquartered in the Nordics, operating across 30 countries and 80 production sites with a workforce of 18,000 employees and net sales of EUR 3.4 billion. The organization produces a diverse portfolio of packaging solutions and manages globally distributed assets with varying maturity levels and operational practices.
80
Sites worldwide
18K
Employees
€3.4B
Net sales
The Challenge
Rapid commercial growth and a diversified footprint had created operational variability across the client's network. Facing rising conversion costs and persistent productivity losses, the company required a unifying operating model capable of:
- Reducing waste and cost leakage: Fragmented practices and uneven operational standards led to productivity inefficiencies across multiple facilities
- Building internal capability: A lack of structured TPM expertise limited the organization’s ability to deploy improvement processes consistently
- Sustaining progress during disruption: COVID-19 travel restrictions created a barrier to traditional onsite engagement, threatening momentum and adoption
- Scaling best practices: Existing success stories were not systematically replicated across the network, slowing improvement cycles and limiting cultural integration
Real Results Achieved Together
Through a structured TPM rollout anchored in lighthouse plants and scaled across the network, EFESO helped the organization embed performance routines, develop internal coaches, and capture measurable operational and financial impact.
€1M
Total run rate cost savings in Year 1 from 30 improvement teams
30
TPM coaches trained across the global network
-50%
Reduction in cost per participant due to remote delivery model
Transformation Impact
- Implemented a unified TPM system including audits, Gemba routines, digital training modules, and skills assessment matrices
- Enabled global knowledge-sharing across improvement teams and production sites
- Delivered capability uplift through a hybrid remote and onsite coaching model adapted to pandemic restrictions
- Established an operating model that accelerates deployment while protecting cultural consistency
Our Approach
EFESO launched a comprehensive TPM (WCOM™) program across a phased network deployment model. The first year focused on lighthouse plants to validate methodologies, develop capability, and prove value. A second deployment wave extended the model to additional lighthouse and satellite sites, ensuring rapid scalability.
Due to COVID-19 restrictions, EFESO introduced an innovative remote delivery model supported by local consultants. This included virtual coaching, interactive Process Kaizen Engineer (PKE) skill development, and digital learning assets complemented by selective onsite interventions. The hybrid model accelerated knowledge transfer, reduced per-participant costs, and maintained implementation momentum.
Systems were put in place for skills matrices, performance audits, training delivery, and routine Gemba rounds—enabling sites to adopt standardized processes, share best practices, and reinforce behavioral change.
Related Services
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Ready to Transform Your Manufacturing Operations?
- Achieve sustainable cost savings while building internal capability across your global operations
- Stop losing productivity to unplanned downtime and inefficient processes
- Join leading manufacturers who have successfully implemented TPM programs that deliver measurable results
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