Our client is a multinational leader in packaging solutions, specializing in flexible, food, and fiber packaging. With operations in more than 30 countries and over 100 manufacturing plants worldwide, generating €4.2 billion in net sales annually. Positioned as a global specialist, they face an increasingly competitive industry, with challenges ranging from high material losses and inconsistent site practices to a need for a continuous improvement culture. Despite a strong focus on cost management, they sought sustainable, capability-building solutions to ensure lasting impact and resilience.
Key Challenges
- High material loss compared to industry benchmark and Material waste reduction forced by market downturn
- No standard way of working across sites
- No Continuous Improvement culture
- Difficulty in Cost Deployment approach adoption
- Difficulty in on-site delivery due to pandemic
- Very strong cost-focus, but struggling to give capability development the right priority, for securing sustainability of the savings
Approach & key success factors
- Design and implementation of a bespoke Operational Excellence Program with tighter focus on material waste reduction in 25 plants, in 23 countries, over 5 years
- Global academy implementation with remote & on-site delivery coaching technologies
- Standard loss analysis approach supported by dashboarding, including operational & financial benefits planning and tracking capability development
- Robust Program Management following the roll out of cost deployment from the start
- Focussed follow up and reporting governance
- Leadership development program.
- Implementation of a global assessment system, including plant, pillar and team assessments
Main results
- >40M€ savings
- >€200M€ losses identified
- Waste reduction for 4,5 million CO2 equivalents
- 1400 teams launched
- 9000 people coached and trained
- 200 certified trainers
- 88 improvement projects with an annual potential of 5,3M€ waste reduction
