the case study in a nutshell

Food & Beverage

Lead Time
20-60 days

Related Solution
Loss Hunter

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This client is a multinational manufacturer of confectionery, pet food, and other food products, looking for a structured approach to loss identification and elimination. We have developed a customised solution for this purpose, launching a local pilot and further extending it to the wider organisation. We have worked in close contact with the client production and IT team to ensure users engagement and solution adoption.

Estimated 5-15% reduction in Total Delivered Cost

Precise identification and localization of losses and immediate cost impact analysis of any potential improvement.

One single source of truth for financial and operational data for more than 100 sites.

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Customer Profile

Amplifon S.p.A. is an Italian company that deals with the design, application and marketing of hearing aids. It is present in 29 countries and on all 5 continents, with more than 11,000 points of sale and around 16,000 employees and collaborators, and a turnover of 1.4 billion Euros. With the acquisition of GAES plant (Barcelona, Spain) in 2018, - has consolidated its worldwide leadership reaching a global market share of 11% of the retail hearing care market.



To design, validate and formalize a methodology in the Barcelona plant expandable to the whole EMEA region, with the following goals:

  • develop an earmolds integrated EMEA supply chain, capable of up to 600k earmolds per year;
  • reduce cost by 4.6 mEUR per year by improving sourcing and production effectiveness and efficiency, lowering the per full industrial cost from 13.9 to 10 EUR/unit;
  • maintain/improve current Service Level



We have developed from scratch a Digital Twin in order to:

  • simulate all possible future scenarios, obtaining precise calculation of lead times, service levels and saturations;
  • validate the re-layout/material flow hypothesis before any intervention;
  • find the optimal configuration in terms of allocated FTEs and shifts for any possible demand which yield maximal throughput.

We have also designed an OCR-based real-time digital traceability and jobs scheduling system, integrated with the existing ERP, for guaranteeing the optimal scenario in case of unpredictable demand and jobs priorities.



Customer profile

A multinational manufacturer of confectionery, pet food, and other food products and a provider of animal care services, with US$33 billion revenue and multiple plants located globally.



The client needed a way to provide clear visibility and understanding of operational losses, their drivers and impacts. In particular

  • To facilitate the computation of losses by assessing different elements such as: management, energy, material, labor, etc.
  • To enable moving away from brainstorming improvement ideas to openly and systematically working to identify opportunities
  • To highlight priority areas so the site can plan resources and execute loss optimisation/elimination activities for what matters most, now and few years ahead


Our solution

We have designed and developed a web-based tool, tailored to the client's P&L structure and loss tree elements

  • We have Delivered a simple and transparent way to show how losses are linked to costs, and identify improvement areas and activities of focus
  • We gave the client support all the way to have one single tool ready to be used across all the segments and plants
  • Such solution was developed ready for AI/ML and automatic data ingestion

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