Our client is a global leader in food packaging, operating across 116 locations in 37 countries. Specializing in sectors such as Flexible, Food, and Fiber packaging, the company has a strong commitment to sustainability and operational excellence. In 2023, the client reported net sales of EUR 4.2 billion. Despite having an established Operational Excellence (OpEx) program in place across most of its plants, the company needed to further optimize its processes to reduce material waste and lower its carbon footprint.
Key Challenges
Market downturn forced the need to speed up material waste reduction Significantly reduce waste, productivity losses and conversion costs OpEx journey started and capability build needed to continue Become the first choice in sustainable food packaging
Approach
The client already had an OpEx program started in most of their plants when the market downturn hit. To quickly ensure quick results on bottom line a program was launched based on the OpEx principles but with tighter focus on material waste reduction.
A common loss analysis approach supported by a standard playbook was implemented to facilitate best practice sharing and horizontal expansion of best working methods Remote virtual delivery coaching technologies were used combined with on-site coaching from local consultants in each country.
Focussed follow up and reporting governance drove the success. More hands-on local coaches were utilised to drive the outcomes.
Results
- 88 improvement projects with an annual potential of 5,3 MEUR addressing waste reduction
- Capability build: 88 trained team coaches, 350 persons trained as loss eradication team members
- The waste reduction equals 4,5 million CO2 equivalents
