-55%
Waste reduction (from 12.5% to 6.8%)
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.
Industry: Packaging
Service: Manufacturing
Service: Operational Excellence
Service: Operations Strategy and Transformation
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
“
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.
€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.
Our Approach
EFESO guided the client through a structured WCOM™ implementation focused on data-driven problem-solving and capability development.
- Data and Prioritization
• Implemented a data collection system by defect mode.
• Applied a QA Matrix to prioritize key issues. - 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. - Sustainment and Capability Building
• Introduced routine management practices.
• Developed employee skills and ownership to sustain results.
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- Unlock hidden value in your production process and turn material waste into bottom-line results
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