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CASE STUDY > FERRERO

How Ferrero Turned 5S Practices into a Daily Work Habit of 600 Workers Using VR Training

Ferrero boasts 36 manufacturing plants and roughly 50,000 employees across the globe. Ferrero follows the famed 5S methodology to ensure its variety of chocolates and confectionery products are manufactured safely and efficiently, without a drop in quality.

Project at a glance

5S training, reimagined in VR
Deployed to 500–600 workers
Positive reception from Global EHS
Scaling to 3 modules, paired with new LMS

5S training, reimagined in VR
Deployed to 500–600 workers
Positive reception from Global EHS
Scaling to 3 modules, paired with new LMS

Teaching the importance of following quality and safety procedures

Ferrero follows the 5S methodology to ensure its food products are manufactured efficiently, maintain high-quality, and remain safe from contamination.

The 5S methodology is not a one-time compliance exercise. It’s a daily habit that workers must follow and internalize deeply.

Manuals and classroom instruction aren’t enough to ingrain this habit among workers. Ferrero's Center of Excellence, the team driving the company's digital transformation, sought a training solution that could change on-the-floor behaviour.

Ferrero follows the 5S methodology to ensure its food products are manufactured efficiently, maintain high-quality, and remain safe from contamination.

The 5S methodology is not a one-time compliance exercise. It’s a daily habit that workers must follow and internalize deeply.

Letting workers feel the consequences of non-compliance in VR

AutoVRse built a VR-based 5S training module for Ferrero, translating the standard five-pillar framework into an interactive, hands-on experience.

Rather than hearing about the consequences, workers experience them directly, first-hand, in the VR module. Since the entire training happens inside a virtual environment, workers face no real risk—to themselves, equipment, or products.

AutoVRse built a VR-based 5S training module for Ferrero, translating the standard five-pillar framework into an interactive, hands-on experience.

Using VR training to trigger a plant-wide 5S culture

Step-by-step, the module covers each of the five pillars of the 5S method.

Sort: Separating essential items from non-essential ones

Teaches how to tell the difference between on-the-floor items that are necessary and unnecessary. Reinforces how removing non-essentials reduces clutter-related accidents.

Straighten: Making essential items easily accessible

Covers how to arrange tools, materials, and equipment. Explains how the correct arrangement reduces errors and the effort required.

Shine: Inspecting, cleaning, and maintaining equipment and tools

Teaches how to spot leaks, defects, and abnormalities. Educates on the critical role the step plays in preventing minor hazards from ballooning to major ones.

Shine: Inspecting, cleaning, and maintaining equipment and tools

Teaches how to spot leaks, defects, and abnormalities. Educates on the critical role the step plays in preventing minor hazards from ballooning to major ones.

Standardize: Codifying best procedures for future repetition

Explains how standardization prevents the workplace from sliding back into disorder. Covers how visual cues, checklists, etc. can be used to standardize 5S conditions.

Sustain: Continue following the right procedures long-term

Teaches how to turn 5S into a routine that doesn’t stop, the moment training ends. Explains how regular audits, ownership, and accountability systems are all key in long-term compliance.

Sustain: Continue following the right procedures long-term

Teaches how to turn 5S into a routine that doesn’t stop, the moment training ends. Explains how regular audits, ownership, and accountability systems are all key in long-term compliance.

5S evolves from a checklist to a daily habit

The 5S VR training module was deployed to 500–600 workers on Ferrero's Pune plant floor. This initial test group revealed the habit-forming potential for 5S VR training.

AutoVRse also demoed the 5S module for Ferrero's Global EHS team. The reception from the global team was overwhelmingly positive.

Testament that shifting procedures from a checklist to a habit resonated both on the plant floor and at the executive level.

Scaling from a single plant to a full training eco-system

Following the initial 5S pilot, discussions have moved toward scaling the programme with two additional training modules.

Alongside the three modules, Ferrero is also in talks with AutoVRse to build a dedicated LMS specifically for measuring workforce performance in all their VR training modules. An LMS that’ll be separate from Ferrero’s existing LMS system.

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