3
Manufacturing sites across the US
Accelerated Operational Transformation Post-Acquisition
A major rice manufacturer faced the complex transition from family ownership to private equity, which required higher performance standards across rice milling and packaging operations. Working together, delivered a comprehensive operational transformation program spanning manufacturing, warehousing and automation. The engagement transformed operations across three sites, establishing sustainable performance improvements.
Food & Beverage
Private Equity
Cost and Value Engineering
Manufacturing
Operations Strategy and Transformation
Procurement
Supply Chain
Our Client
A major rice manufacturer operating across the US, with facilities in two states. The company specializes in rice milling and packaging, sourcing raw rice from farms for processing and retail distribution. Beyond its core rice business, it operates a profitable spice and beans division, primarily serving restaurants. Following its acquisition by an investment firm, the organization required cultural and operational transformation to meet performance expectations.
2
States with operations
2
Core business segments
Multiple
Product categories (rice, spices, beans)
The Challenge
The transition to private equity ownership revealed fundamental operational constraints, limiting its performance potential.
- Packaging inefficiencies: Low OEE (45-49%) and poor production levels drove excessive overtime, impacting both workforce morale and profitability while creating bottlenecks in daily operations
- Warehouse constraints: Undersized facilities relative to production volume created organization challenges, with high-volume rice filling warehouses within days, making pallet location and inventory management extremely difficult
- Transportation reliability: A dependence on lowest-cost carriers resulted in frequent no-shows, unsuitable vehicle conditions for food transport and delays that compounded warehouse capacity issues, with truck turnaround times exceeding 2.5 hours
Real Results Achieved Together
The transformation established a performance-driven operating model across all functional areas, from shop floor operations to strategic automation initiatives. Working alongside the company’s teams we implemented sustainable improvements that fundamentally changed how the organization operates and delivers value.
+44%
Plant throughput increase
+100%
Spice line throughput improvement
+30%
Packaging efficiency gains
Transformation Impact
- Reduced truck turnaround time by one hour while achieving consistent on-time placement
- Eliminated packaging material shortages through MRP process redesign
- Installed continuous improvement mindset across shop floor operations
- 90% first-time-right production
Our Approach
We deployed a team of five consultants for an initial six-week operational analysis, examining manufacturing, packaging, milling, warehousing, transportation and procurement to identify bottlenecks and improvement opportunities. The implementation was delivered through structured workstreams including Kaizen events, line balancing and visual management installations across packaging operations.
We established daily production tracking dashboards, implemented locators and staging areas for warehouse optimization and introduced carrier scorecards with KPI-based accountability. The team developed a three-year CapEx plan while relaunching stalled automation projects including a high-speed spice packaging line.
Throughout the engagement, we conducted operator training on standard work procedures and embedded daily huddles, KPI reviews and structured operational cadences. The extended three-month sustainment phase ensured complete handover to the internal team, with all improvements fully integrated into daily operations.
Related Services
Rising costs demand optimization from design through production. We apply cross-functional value engineering, zero-based redesign, and continuous cost tracking to protect margins.
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Material costs and supplier volatility threaten profitability. We unlock savings through strategic sourcing, supplier collaboration, and digital procurement transformation.
Supplier complexity obscures 70% of your value creation. We strengthen networks through supplier development programs, risk mitigation strategies, and collaborative innovation platforms.
Facing Similar Post-Acquisition Challenges?
- Struggling with operational inefficiencies limiting portfolio company value creation
- Seeking rapid transformation from family business culture to performance excellence
- Ready to unlock hidden capacity through systematic operational improvements
Discover More Clients Results
15%
Improvement in delivery performance (OTIF)
Resources Mining and Processing
EFESO supported KME Group in integrating Sales & Operations Planning (S&OP) with its broader supply chain, driving strategic alignment, improving delivery performance by 15%, and reducing metal stock by 33%, resulting in a €100 million financial impact.
€90M
in Opportunities identified during the program
Chemicals
A global chemical company launched a joint performance improvement initiative with EFESO across twelve plants on four continents. Significant improvements in cost drivers and margins were achieved.
-15%
Reduction in indirect purchasing costs
Automotive and Commercial Vehicles
Private Equity
Industrial machinery manufacturer faced complexity in custom equipment production. We implemented modular design principles, standardized components, and optimized project management, reducing lead times by 40%.
€2.7B
Total savings achieved
Automotive and Commercial Vehicles
Automotive supplier needed profitability improvement for complex drive components. We established end-to-end value optimization, supplier collaboration, and cost engineering, improving margins across entire value chain.
-10%
CapEx reduction for new buildings
Aerospace & Defense
Global aerospace manufacturer struggled with 180-site real estate complexity. We established centralized intelligence service, data-driven governance, and sustainability tracking, guiding €7 billion in asset decisions.
8-10%
Transformation cost reduction achieved
Aerospace & Defense
Aerospace corporation faced fragmented digital infrastructure across divisions. We launched enterprise-wide transformation, integrated systems, and drove operational excellence, reducing operational costs by 10%.
-17%
Lead time reduction
Industrial Manufacturing
Packaging machinery group needed lead time and inventory optimization. We conducted comprehensive value stream analysis, identified bottlenecks, and developed transformation roadmap, targeting 40% reduction potential.
~$30M
Total value improvement identified
Food & Beverage
Private Equity
Food ingredients supplier required rapid turnaround after quality issues. We stabilized operations, rebuilt quality systems, and restored customer confidence, returning to full production within 6 months.