Client situation & approach
The client is a world-leading global packaging manufacturer headquartered in the Nordics but present in 30 countries and 80 sites around the world with18.000 employees and net sales of EUR 3.4 billion.
The client needs to significantly reduce waste, productivity losses and conversion costs, so they approached EFESO as we have done extensive work and TPM based operations achieving excellent results worldwide with a similar operational entity and structure.
To achieve the desired goals:
- EFESO launched a complete TPM (WCOM™) program in a set of lighthouse plants worldwide first year (2020) followed by another set of lighthouse plants in the second year (2021) together with a set of satellite plants
- The COVID-19 environment required extensive virtual delivery of coaching combined with on-site coaching from local consultants in each country. They used ground-breaking remote PKE (Process Kaizen Engineer) based skill development training using interactive tools and on-site coaching
Results
- Performance improved with a total run-rate cost savings Y1: 1 m€ from 30 improvement teams despite full COVID-19 environment
- Capability improved with 30 trained TPM coaches and 150 people involved in systematic improvement work, global learning and best practice sharing between sites
- Systems implemented covering skills assessment matrix and web-based training, audit system and Gemba rounds
- A benefit of the remote delivery was a reduced cost per participant by 50% in Year 1 (2020) and, in 2021 remote delivery combined with local on-site delivery, offers full flexibility in the training and adoption of culture and processes