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WCOM™ Cuts Waste 55% and Delivers Savings in Packaging

A leading producer of multi-layered packaging bags partnered with EFESO to launch a pilot project aimed at reducing waste by 30% in its main nozzle machine. Through WCOM™ implementation, root cause analysis, and capability development, the company achieved 55% waste reduction, annual savings of €250k, and a strengthened culture of machine care.

Packaging
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Parallaxe

Our Client

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.

“

At the end of this pilot project journey I could see that the involvement of our employees in reducing losses was possible and effective

“
Industrial Manager
Parallaxe

The Challenge

The company aimed to reduce waste by 30% in its main nozzle machine, as approximately 60% of its product cost was composed of raw material. The pilot also sought to validate the WCOM™ method’s effectiveness and support people development.

  • High raw material costs: Representing around 60% of product value.
  • Need to reduce waste by 30%: Focused on the main nozzle machine.
  • Pilot project objective: Assess method efficiency and people engagement.

Real Results Achieved Together

The pilot demonstrated the effectiveness of the WCOM™ methodology, delivering substantial waste reduction and savings while improving collaboration and technical ownership on the shop floor.

-55%

Waste reduction (from 12.5% to 6.8%)

€250K

Annual savings

29

collaborators trained in new standards

Transformation Impact

  • Strengthened teamwork between Operations and Maintenance.
  • Introduced a new culture of machine care among production personnel.
  • Established standard routines and preventive practices to maintain performance.


Parallaxe

Our Approach

EFESO guided the client through a structured WCOM™ implementation focused on data-driven problem-solving and capability development.

  1. Data and Prioritization
    • Implemented a data collection system by defect mode.
    • Applied a QA Matrix to prioritize key issues.
  2. Process Stabilization and Root Cause Elimination
    • Re-established basic operating conditions (cleaning, inspection, lubrication, tagging).
    • Conducted root cause analysis of priority defects.
    • Deployed countermeasures to prevent recurrence.
  3. Sustainment and Capability Building
    • Introduced routine management practices.
    • Developed employee skills and ownership to sustain results.

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  • Join industry leaders who’ve achieved breakthrough waste reduction and lasting operational excellence

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