Mars Wrigley

Challenge

Mars Wrigley faced mounting pressure to accelerate workforce readiness without compromising the quality and safety standards required in its high-volume manufacturing environment. Traditional training methods were time-intensive, limited by instructor availability, and required direct access to live production equipment, creating scheduling bottlenecks and potential operational disruptions. The company recognized that improving training efficiency would not only reduce downtime but also unlock significant gains in productivity and product output.

Compounding these issues was the need to prepare employees to work confidently with advanced machinery before entering live environments. The complexity of processes and inspections required repeated exposure and hands-on practice, which is not always feasible during in-person sessions. Mars Wrigley needed a training approach that could deliver consistent, high-fidelity learning at scale while ensuring operators achieved full proficiency from day one.

Solution

To address these challenges, Mars Wrigley identified a high-impact opportunity area: enhancing employee familiarity with complex machinery and critical operational processes. They commissioned a suite of virtual reality (VR) simulations designed to deliver repeatable, hands-on learning in a fully controlled, risk-free environment.

The VR program included tablet-based trainer tools that support collaborative, multiplayer classroom experience, enabling instructors to guide and assess employees in real time. Learners could freely explore equipment, safely practice troubleshooting and inspection tasks, and complete proficiency checks that validated readiness before stepping onto the production floor.

Results

The adoption of virtual reality training has driven dramatic improvements in both efficiency and workforce performance. Mars Wrigley achieved a 50% reduction in training time, enabling faster onboarding and more agile upskilling across teams and facilities.

These efficiency gains translated into meaningful business outcomes. The company saw a 10% increase in knowledge retention, 18% growth in employee efficiency compared to non-VR trainees, and a 32% boost in product output, all contributing to an impressive 30x return on investment within the first 6-months post-deployment. The VR program continues to scale to other sites and divisions within Mars as a transformational model for operational training and performance enablement.

REDUCED TRAINING TIME

EMPLOYEE RETENTION INCREASE

INCREASE IN EFFICIENCY