Zaleco Reduces Scrap Rate by 20% and Increases Operational Availability 30% with In-Process Quality Control

Zaleco SRL, a Romanian smart engineered packaging solutions provider, faced increased demand that exposed limitations including avoidable downtime, communication gaps, limited real-time information access, and production reporting issues. Over 90% of their solutions are customized, making standardization difficult.

Deployed Tulip to build digital work instructions with embedded PDF files, images, and videos, quality inspection apps with defect codes and reference images for Pareto analysis, and a custom production management dashboard for real-time operational visibility. Citizen developer Alin Salagean built and maintained all apps internally.

Reduced scrap rates by 20% in just two months through real-time tracking. Increased operational availability by at least 30% through improved downtime management. Achieved double-digit cycle time improvements through process optimization and inline quality checks.

A 20% scrap reduction in 2 months demonstrates that real-time visibility into defect data drives rapid process corrections. Zaleco's Packaging industry use case shows Tulip's versatility beyond traditional discrete and process manufacturing.