I Background
The manufacturer had been focusing on improving operational efficiency and product quality as part of its ongoing Zero Defect initiative. To accelerate the transformation and embed continuous improvement more firmly into everyday operations, the company sought external expertise.
Mantec was selected to lead a comprehensive improvement programme. The objective was to strengthen the management practices, leadership capabilities and improvement routines needed to support sustainable progress across the production organisation.
II Analysis
The partnership began with an extensive analysis of the company’s production processes. Detailed operational studies were conducted across multiple production lines, with observations covering film production, printing and package forming.
The analysis identified several opportunities for improvement in management systems, production leadership and continuous improvement processes. These findings provided a clear basis for implementation and helped focus the programme on those practices with the greatest potential to improve daily performance.
III Implementation
Management Operating System
A streamlined meeting structure was implemented, including daily machine and factory meetings. This improved communication and strengthened operational alignment across departments.
Operational key performance indicators (KPIs) were established to track performance against plans. Roles and responsibilities were also clarified, reducing inefficiency and improving decision-making processes.
Together, these changes created a clearer rhythm for daily control and enabled teams to identify deviations earlier, follow performance more consistently and coordinate actions across functions.
Production Leadership and Continuous Improvement
A “deviation management” process was developed and implemented to enable more effective problem solving through root cause analysis.
Cross-functional improvement teams were formed to drive process improvements and reduce waste and inefficiencies. A Plan-Do-Check-Act (PDCA) methodology was also introduced and integrated into the company’s ticket system, providing a consistent way to manage, follow up and track improvement actions.
By connecting daily deviations with structured improvement work, the company strengthened its ability to address issues systematically and build continuous improvement into everyday operations.
Comprehensive Training Initiatives
Structured coaching and training programmes were implemented for operators, first-line managers and technicians, fostering a culture of accountability and leadership excellence.
The training covered root cause analysis and practical problem-solving methodologies. The onboarding process for new employees was also improved, enabling faster and more efficient integration into the production environment.
IV Results
After six months, the programme had delivered significant and measurable results:
- A clearer and more efficient structure for daily control
- Stronger problem-solving capabilities at all levels
- Improved collaboration across departments, supporting smoother workflows and fewer bottlenecks
- A solid foundation for future growth and development
- A positive trend in waste reduction across multiple production lines, with some lines consistently performing better than the 2025 targets
The transformation demonstrates how clear management routines, capable leaders, structured problem-solving and active cross-functional collaboration can turn a Zero Defect ambition into practical ways of working. By strengthening these foundations, the manufacturer has created the conditions for continued improvement in quality, efficiency and operational performance.
Would you like to explore the operational potential in your organisation?
Book a free 45-minute consultation with us:
Denmark – Bent Hansen
bent.hansen@mantec.eu
+45 20 91 46 36
Finland – Eero Vuorensola
eero.vuorensola@mantec.eu
+358 40 54 45 200
Sweden – Göran Svensson
goran.r@mantec.eu
+46 70 631 86 18
Norway – Jan-Erick Olsen
jeolsen@mantec.eu
+47 922 68682
Other countries – Kjetil Barfelt
kjetil.barfelt@mantec.eu
+47 913 13 131
