Increased completion rates for audits and quality checks up to 46% in some areas
Reduced missed checks from an average of 7 per period to only 2
Saved approximately 2 trees per month by reducing paper usage
Accelerated rollout across value streams, completing in 3 days instead of 1 week as planned

The Challenge

Mars Wrigley, the confectionery division of Mars, Incorporated, produces some of the world's most popular candy brands like M&M's, Snickers, Skittles, and Wrigley's chewing gum. At the Mars Wrigley facility in Waco, the team faced significant operational hurdles that hindered the efficiency and effectiveness of their quality management processes.

Inefficient Data Capture and Low Engagement

Matthew Flores, Digital Continuous Improvement Lead at the Mars Waco facility, communicated the primary challenge was the outdated and inefficient method of data capture for connection points, and critical interactions in the production process where components, ingredients, and packaging materials converge. These connection points are essential for ensuring product quality and consistency, yet the team relied heavily on manual entries, which proved to be error-prone and time-consuming.

Additionally, the facility struggled with low submission rates and user engagement regarding Continuous Improvement Opportunities (CIO) and quality check completions.

These metrics are crucial for maintaining high standards in production and ensuring the overall success of the facility's output. However, the lack of a streamlined process led to minimal participation from staff, thereby reducing the potential for operational improvements and innovation.

The Implementation

Mars Wrigley chose to use Weever software; a comprehensive digital tool, to address the inefficiencies and challenges at their facility in Waco, Texas. This solution transitioned from outdated paper-based systems and cumbersome physical whiteboards to a sophisticated, cloud-based platform that facilitates real-time data capture and analysis.

The implementation of the Weever solution at Mars Wrigley's Waco facility began with a strategic rollout in one of the production value streams. This focused approach allowed the team to closely monitor the integration and performance of the software within a controlled environment, ensuring that any issues could be addressed promptly without widespread disruption.

The initial success in the pilot value stream was quickly evident, as the digital tool effectively streamlined data capture and enhanced operational visibility.

Encouraged by these positive results, the facility rapidly extended the use of the Weever solution to other value streams. What was anticipated to be a lengthy process turned out to be swift and efficient. The initial plan had allocated a whole week for each value stream's integration, but the actual implementation often took just three days. This discrepancy between expectation and reality highlighted the ease of adoption and user-friendly nature of the Weever software, significantly accelerating the digital transformation process across the facility.

Expansion to Other Use Cases

Following the successful initial rollout, Weever's functionality was expanded to encompass a broader range of operational use cases. This expansion was aimed at leveraging Weever's capabilities to further enhance safety and quality control processes, which are critical to the confectionery manufacturing environment.

Daily Safety Triggers: The software was configured to integrate daily safety triggers, automating the reporting and monitoring of safety-related incidents. This feature has improved the responsiveness to potential safety issues, thereby reducing risk and enhancing worker safety.

Quality Documentation and Sensory Evaluations: The Weever solution also facilitated the digitalization of quality documentation processes. This includes sensory evaluations critical in ensuring the consistent quality and taste of confectionery products. By digitizing these processes, Mars has been able to maintain rigorous standards more efficiently and with greater accuracy.

Expiration Date Validations: One of the specific processes that saw substantial improvement with digitalization was the validation of expiration dates. Previously managed through paper records, which were cumbersome and prone to errors, the expiration date validations were moved to a digital platform. This change not only streamlined the process but also improved data reliability, making it easier to ensure compliance with food safety standards.

"Having a tool that's so adaptable and easy to use has not only saved us time but has also made our work environment much more enjoyable."

The Results

Performance Improvements

The implementation of Weever at the Mars Waco facility has led to significant performance improvements, notably in the areas of compliance and operational efficiency. There has been a remarkable increase in the completion and compliance rates for various audits and quality checks, with figures soaring up to 46% in some areas. This boost can be attributed to the streamlined and transparent processes enabled by Weever, which facilitates real-time monitoring and prompt corrections.

The reduction in missed checks has been a critical outcome. Previously, the facility averaged seven missed checks per period, a figure that has since decreased to just two. This improvement is particularly significant in maintaining stringent quality standards and ensuring consistent product excellence. Additionally, the digitalization of processes like expiration date validations has enhanced efficiency, reducing time spent on manual validations and decreasing the likelihood of errors.

Environmental and Operational Impacts

The adoption of Weever has also had a positive impact on Mars Wrigley’s sustainability goals. One of the most notable achievements in this area has been the environmental savings—specifically, the reduction in paper usage, which has effectively saved approximately two trees per month. This contribution aligns with Mars Wrigley's broader sustainability initiatives, such as reducing carbon footprints and enhancing resource efficiency.

Internally, the success of Weever's implementation was celebrated and the Waco site even received special recognition in this company-wide video.

Conclusion

The Weever solution at Mars Wrigley's Waco factory has improved operations across numerous areas, demonstrating the power of digital transformation in modern production. Its integration has improved operational efficiency, compliance, and environmental sustainability. Usage of Weever has decreased missed inspections, expedited quality and safety processes, and supported business sustainability goals, including paper reduction and forest conservation.

Interested in learning more about Weever's ability to enhance production efficiency?

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“Having cloud-based forms on devices around the facility makes them so much more accessible, which makes it painless for operators to quickly provide a report.”

Johanna Velez, VP Quality Assurance

"Weever is really user friendly and will have a massive positive impact on our operations and training team."

Mel Cadle - Op Ex Lead Process Engineer

“It’s shifted our safety culture because now we are much more focused on what we should be looking at.”

Kody Crossen, Operations Manager of EHS

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