A global manufacturer of plastic packaging solutions for consumer products employing more than 4,000 people and an annual turnover exceeding €380 million.
Key Challenges
- High number of customer complaints, with a risk of losing customers
- High frequency of process stops, initially reaching 300 per week
- Poor basic equipment conditions
- Lack of performance monitoring in daily operations
- Inadequate SOPs for key processes and insufficient process control
Approach & Key Success Factors
- Focused Potential Analysis
- Duration: 3 weeks
- Full integration of plant team and management
- Optimization approach covering all quality-related aspects
- Equipment conditions and management
- Processes and SOPs
- Performance control system
- Operator capabilities
- Boost progression cycle to 14 weeks
- Systematic project management approach
- Rigorous project governance with weekly management reviews
- Plant team in the lead, supported by consultants on the shopfloor
Main Results
- Monthly customer complaints reduced by 44%
- Weekly process stops decreased by 56%
- Standardized PCS and performance metrics implemented
- Key SOPs optimized, incl. color change and start-up procedures
- Basic conditions restored for injection moulding machines
- Operator capability gaps significantly reduced
