Discover how EFESO works side by side with clients across industries to achieve measurable, lasting impact. Each story captures the challenges our clients faced, the actions we took together – from boardroom to shop floor – and the tangible operational and financial results delivered.
45K m²
Optimized factory layout (reduced from 52 Km²)
Industrial Manufacturing
Factory Planning
Manufacturing
Smart Factory
Creating a solid, structured plan for the material flow of its production and validated the static forecast, enabling the factory to increase the output with the existing machinery.
~10K m²
Optimized production layout
Industrial Manufacturing
Factory Planning
Manufacturing
EFESO developed a factory planning concept for a new electronics plant, optimizing layout, production flows, and functional integration to enable efficient operations and future scalability.
€260K
Annual benefits achieved
Chemicals
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Restructured maintenance operations at chemical specialty polymers site, delivering €260K annual savings through optimized processes.
+800
Additional storage positions identified
Consumer Goods and Luxury
Factory Planning
Logistics and Distribution
Manufacturing
Supply Chain
EFESO redesigned warehouse layout and internal logistics flows for a global consumer goods manufacturer, increasing storage capacity and improving operational efficiency in a brownfield production environment.
8%
EBITDA increase through improved operational productivity
Consumer Goods and Luxury
Manufacturing
Operational Excellence
A global luxury fashion house aimed to improve operational productivity and achieve target EBITDA despite complex production challenges.
30%
Reduction in unplanned stops over 2 pilot lines
Consumer Goods and Luxury
Manufacturing
Operational Excellence
A global consumer health company implemented an operational transformation, delivering a 30% reduction in unplanned stops and validated standards for global rollout, supporting a shift to a proactive operational culture.
~10K m²
Optimized factory footprint
Aerospace & Defense
Digital & Ai
Factory Planning
Industrial Strategy, Operating Model & Transformation
Manufacturing
Operations Strategy and Transformation
Design of a future-proof, modular drone factory enabling multi-product manufacturing, rapid scalability, and optimized investment for aerospace defence applications.
Up to 37%
Increase in effective production capacity through downtime and changeover reduction
Life Sciences
Manufacturing
Operations Strategy and Transformation
Supply Chain
A global pharmaceutical manufacturing company implemented a structured Maintenance Excellence Program combining diagnostics, pilot execution, and model design.
35%
Reduction in logistics headcount through automation
Food & Beverage
Cost and Value Engineering
Factory Planning
Manufacturing
EFESO supported the design and realization of a 30,000 sqm greenfield dairy plant, delivering an integrated factory planning concept with full automation and optimized material flows and scalable operational concepts.
+10K
Pallet positions created through optimized DC layout expansion design
Life Sciences
Factory Planning
Manufacturing
Smart Factory
EFESO conducted a feasibility study for a new 10,000-pallet automated warehouse in Romania, optimizing logistics design, layout, and CAPEX to enable scalable, efficient pharmaceutical distribution.
10%
CAGR in assembly labor productivity in participating plants
Automotive and Commercial Vehicles
Leadership & Change Management
Manufacturing
Operational Excellence
People and Organization
EFESO implemented a global award-based operational excellence program for a leading automotive OEM, boosting productivity, cost efficiency, employee engagement, and sustainability across the factory network.
+$10M
Annual margin improvement through better loss control and operational routines
Oil & Gas, Sustainable Energy
Manufacturing
Operational Excellence
A major refinery embed lean practices, improve operational performance, and strengthen cultural engagement, generating significant financial and organizational impact.
16–23%
Potential cost savings identified on key bill of materials components
Automotive and Commercial Vehicles
Cost and Value Engineering
Manufacturing
Product Profitability
R&d and Product Development
R&d and Product Profitability
A mid-sized European automotive supplier develop a robust cost model and uncover savings for a high-voltage battery module, strengthening internal alignment and negotiation readiness.
90%
Average OTIF achieved in under two years
Life Sciences
Factory Planning
Manufacturing
Operational Excellence
A mid-sized pharmaceutical company achieved measurable efficiency, cost, and delivery improvements at four European sites through EFESO’s Operational Excellence and Digital Transformation programs.
13%
Reduction in release time for high-value APIs
Chemicals
Life Sciences
Manufacturing
Operational Excellence
Smart Factory
A QC lab optimization framework helps a multinational chemical-pharmaceutical company achieved simultaneous gains in productivity, service level, and resource efficiency, delivering measurable improvements in release time, productivity, and FTE requirements without compromising quality.
12
"Golden Rules" implemented for production planning
Industrial Manufacturing
Cost and Value Engineering
Data & Ai
Digital & Ai
Factory Planning
Manufacturing
Smart Factory
Supply Chain
Creating a solid, structured plan for the material flow of its production and validated the static forecast, enabling the factory to increase the output with the existing machinery.
Industrial Manufacturing
Manufacturing
Restructuring & Turnaround
Supply Chain
Transactions and Turnaround
Fact-based restructuring of a complex industrial site, enabling a clear shutdown decision, cash-drain elimination, and a structured roadmap for execution.
40%
Reduction in Capital Expenditures for new production technology
Packaging
Manufacturing
Operational Excellence
A leading global manufacturer of glass containers reduce capital expenditure by 40% in the commercialization of a new glass production technology by applying Value Engineering and Lean Product Development principles.
+30%
OTIF improvement
Life Sciences
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Reengineered Order Management processes for pharma services provider, achieving 30% OTIF improvement to 95% target.
-50%
Reduction in claims
Packaging
Manufacturing
Operations Strategy and Transformation
Global packaging manufacturer deploys WCOM™ across 24 plants, slashing claims and waste 50% while boosting productivity 30%.
+20%
Increase in global production capacity using the same plants
Life Sciences
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Global cosmetics manufacturer implements WCOM™ across 29 plants, achieving 20% capacity gain and 70% OEE.
+8.3%
OEE increase in 3 months
Packaging
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Board manufacturer increased production capacity through WCOM™ implementation, achieving 8.3% OEE improvement in three months.
+25
Percentage points Line OEE improvement at a key site within 6 months
Food & Beverage
Digital & Ai
Manufacturing
Operations Strategy and Transformation
An initiative that improved Line OEE by 25 percentage points and positioned the organization to recover a $15M investment within 18 months.
+50
Global change agents equipped to lead maintenance transformation
Chemicals
Manufacturing
Operational Excellence
People and Organization
Harmonized maintenance across 17 global sites through 50 trained change agents, delivering €50M annualized savings.
Discover measurable outcomes achieved with our clients
See how transformation happens, from boardroom to shop floor
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