Leoni boosts production efficiency and reduces waste with Tork Workflow
About Leoni
Leoni is a global provider of products, solutions and services for energy and data management in the automotive sector and other industries. With 95,000 employees in 32 countries, Leoni generated consolidated sales of US $5.9 billion in 2024.
The challenge
At Leoni’s production facility in Romania, the company needed a more cost-efficient and hygienic approach to wiping and cleaning across different stages of its manufacturing process.
A Tork Workflow™ evaluation of the entire workplace revealed clear opportunities to reduce waste, optimise storage capacity and improve process efficiency. Working together with the local Leoni team, the goal was to identify the most effective and economical cleaning solutions for each phase of production.
Results at a glance
Efficiency
- 1.5 hours of wasted motion saved per shift
- Safer, cleaner working environment
Waste reduction
- 18% material waste reduction
- 18% less toxic waste
- 80% carbon footprint reduction
Experience
- Improved workplace hygiene
- Improved employee and customer satisfaction
Tork solutions
A full analysis and report via Tork Workflow identified several improvement areas common in manufacturing: unnecessary movement, excess inventory and inconsistent wiping processes. Tork then implemented targeted solutions aligned with lean principles and 5S organisation.
Motion waste reduction
Operators were losing time retrieving wipers placed far from workstations. Tork installed the W3 dispensing system directly onto the robot mobile arm and introduced colour-coded wipers for task clarity.
Impact:
- 1.5 hours saved per shift – US $4,370 saved per month
- Reduced interruptions resulting in a smoother workflow
Inventory waste reduction
Leoni previously stocked large quantities of wiping material due to supply chain uncertainty. Tork introduced a weekly replenishment model with tailored wipers supplied locally.
Impact:
- Significant storage space released
- More predictable supply
- Efficient stock rotation
Defect waste minimisation
By introducing Tork dispensing systems and task-based wipers, excessive paper use is prevented, and the protected wipers reduce external contamination risk – supporting more stable, standardised production quality
Impact:
- Reduced overuse of materials
- Lower defect risk and more consistent product quality
- Better hygiene control in sensitive areas
“We are really satisfied with all the solutions provided by Tork. They helped us not only to reduce waste but boost workplace efficiency to the satisfaction of both our employees and customers”, Production Section Manager, Leoni.
Discover Tork Workflow™ for Manufacturing
Find out how Tork solutions can improve workplace efficiency, reduce waste and support more efficient production. With a full report tailored to your facility, Tork Workflow reveals where small changes can deliver big operational benefits.