+3.5K
Employees worldwide
Accelerating Lead Time Reduction and Inventory Optimization Through Segmented Product Maturity Management
A global discrete manufacturing leader faced mounting inefficiencies as a result of product complexity and operational silos. EFESO worked with the company to implement a four-quadrant maturity framework that transformed how teams manage products across their lifecycle. This partnership delivered measurable improvements across seven transformation workstreams.
Industry: Industrial Manufacturing
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: People and Organization
Service: Procurement
Service: Supply Chain
Our Client
This global leader in discrete manufacturing engineers and builds sophisticated machinery for fast-moving consumer goods sectors, including both traditional and next-generation product segments. Based in Italy’s industrial heartland, the company operates across multiple continents with a robust R&D capability and strong legacy of customization for demanding clients. Its offering includes dozens of machine models with modular configurations tailored to unique customer needs.
€600M
Annual turnover
400
Supplier network
4
Maturity-based segments
The Challenge
The organization faced issues common to high-complexity, high-customization manufacturers that threatened profitability and customer satisfaction.
- Product Range Complexity: With machines at various stages–from initial prototypes to long-standing market standards and products nearing obsolescence–the company lacked a unified framework to manage these differing lifecycle needs
- Operational Silos: Coordination between engineering, supply chain and production was fragmented, exacerbating communication lags, duplication of efforts and confusion over ownership for cross-functional processes
- Extended Lead Times and Inventory Overhang: Diverse procedures and ad hoc process adaptations for bespoke orders lengthened manufacturing cycles while parts and subassemblies accumulated in excess, tying up significant working capital
Real Results Achieved Together
The transformation program delivered measurable strategic and cultural impact across the organization. Working alongside client teams, we established distinct processes for each maturity phase that gave employees clear accountability and simplified handoffs.
-17%
Lead time reduction
-38%
Inventory decrease
16
Months implementation
Transformation Impact
- Accelerated product transitions through standardized criteria for launching new models and retiring obsolete ones
- Enhanced organizational clarity with distinct teams and processes for each maturity phase
- Achieved cultural adoption with teams embracing structured collaboration and data-driven decision-making
Our Approach
The project began with a diagnostic phase–detailed mapping of operational flows, review of the machine portfolio and data analysis on historical lead times, inventory turns and process bottlenecks. We segmented the product portfolio based on maturity status into four categories: prototype, industrialization, mature and phase-out. For each segment, we tailored supply chain management, procurement, planning and assembly disciplines.
Prototypes received dedicated engineering teams and agile assembly cells. Industrialization focused on process stabilization. Mature products moved to highly standardized procedures.
Phase-out items were tightly controlled with limited inventory buffers. The approach combined visual management tools, hands-on workshops, KPI dashboards and executive sponsorship. The four-quadrant model provided a shared language and decision-making reference, uniting stakeholders from engineering to shop floor operators.
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Facing Similar Manufacturing Complexity Challenges?
- Struggling with extended lead times and excess inventory across diverse product portfolios
- Seeking to transform operational silos into structured collaboration and clear accountability
- Ready to implement maturity-based frameworks that deliver measurable operational excellence
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