Case study · Packaging
From weeks of shadowing to five days on video.
Aluflexpack Novi replaced peer-to-peer shadowing with REWO video instructions on tablets. New operators on basic machinery now train in five days instead of two to three weeks — without stopping production for training sessions.
Industry
Flexible packaging
Group
Constantia Flexibles
Size
~1,700 employees, 9 countries
Deployment
Standalone — tablets
Aluflexpack is a European producer of custom flexible packaging for the food and pharmaceutical sectors, with around 1,700 employees in nine countries, and is now part of Constantia Flexibles. REWO runs at Aluflexpack Novi, which operates facilities in Umag, Drniš and Zadar.
The challenge
Training that depended on who was teaching.
Aluflexpack trained by shadowing: an experienced operator showed each new hire the job. As the company grew, that stopped scaling.
Weeks to competency
Training a new operator on basic machinery took two to three weeks of shadowing before they were productive.
Production stopped for training
Two weekly two-hour group sessions meant machines stood still while operators learned.
Language barriers
Verbal instruction in Croatian often didn't land with international employees.
Every mentor taught it differently
Peer-to-peer shadowing passed on different methods, leaving gaps in tribal knowledge.
The solution
Video training that runs alongside production.
Aluflexpack used REWO to turn its experts' know-how into video guides operators watch on a tablet — no classroom, no stopped line.
Training without stopping machines
New hires watch step-by-step video guides on a tablet during breaks or machine downtime.
One best way, on video
The team captured the correct way to perform each task once, so every operator learns the same safety and quality steps.
Written in Croatian, delivered in any language
Guides are prepared in Croatian and auto-translated; the video shows what words can't.
Knowledge checked, then re-checked
Digital tests confirm readiness before operators touch the machines, and digital forms re-test them two months in.
The results
Faster to productive, and the line keeps running.
5 days
To train a new operator on basic machinery, down from 2–3 weeks
200+
Production hours a year reclaimed on the affected lines
4 h/week
Of training downtime eliminated
One method
Every new operator learns the same standard way
Onboarding cut to five days
New operators become independent on basic tasks in five days, where shadowing took two to three weeks.
Production capacity back
Removing four hours of weekly training downtime reclaimed 200+ production hours a year on the affected lines — about five weeks of capacity, with no new machinery.
Senior operators freed up
Less shadowing means experienced staff spend their time on production, not repeat explanations.
Training that crosses languages
International workers learn complex machine operations visually, with less reliance on translated manuals.
Customer perspective
“We used to stop production for training. Now we just share a REWO link. Machines keep running and new hires are ready in days instead of weeks.”
Dean Hrvatin, Head of Slitting & Pouches Department, Aluflexpack Novi — Aluflexpack
Bottom line
Onboarding became a source of capacity.
Moving from mentor-dependent shadowing to standardised video training gave Aluflexpack Novi faster onboarding and production capacity back — without new machinery. The company is now extending REWO to recurring annual certifications such as hygiene and safety training, using locked video playback so completion can be shown at audit.
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