+10K
Employees
Achieving a 40% Capital Expenditure Reduction in New Glass Technology Commercialization
A leading global manufacturer of glass containers partnered with EFESO to reduce capital expenditure in the commercialization of a new glass production technology. By applying Value Engineering and Lean Product Development principles, the company achieved a 40% CapEx reduction—far exceeding initial targets—while strengthening technical feasibility, internal alignment, and cross-functional collaboration.
Industry: Packaging
Service: Manufacturing
Service: Operational Excellence
Our Client
One of the world’s largest glass container manufacturers serving the food and beverage industry. The company operates globally and is recognized for its commitment to packaging innovation and continuous process improvement.
€1.4 B
Annual revenue
“[The project] brought out savings we never would have expected—this could be a game changer for how we approach new technology investment in the future.
“
The Challenge
The client aimed to commercialize a major new glass production concept but faced a significant challenge: the high capital expenditure required for the new equipment design. While internal targets sought a 10–15% cost reduction, leadership set a far more ambitious goal of achieving at least a 40% reduction to ensure financial viability.
- Cost pressure: Operating in a highly competitive market with tight margins demanded substantial cost efficiency.
- Internal skepticism: Teams believed the design was already optimized and saw limited potential for further savings.
- Low cost transparency: Many design elements were managed externally, reducing visibility into true cost drivers.
- Perceived disruption: Concerns arose about the time, effort, and potential delays of additional optimization work.
The client engaged EFESO to provide external expertise in value engineering and lean methodologies, ensuring a structured, evidence-based approach to uncover new opportunities and align all stakeholders.
Real Results Achieved Together
EFESO enabled the client to unlock substantial cost reductions and validate the technical and commercial viability of its new production technology, driving long-term competitiveness.
40%
Reduction in Capital Expenditures for new production technology
>25%
Total savings identified from previously unrecognized opportunities
100%
Cross-functional stakeholder participation across design, engineering, and operations
Transformation Impact
- Confirmed the technical and commercial feasibility of the redesigned production technology.
- Identified and realized significant hidden savings, strengthening the investment business case.
- Enhanced collaboration and buy-in across engineering, procurement, and operations.
- Established a repeatable framework for future technology efficiency projects.
Our Approach
EFESO implemented an intensive, data-driven approach combining Value Engineering, Lean Product Development, and structured stakeholder engagement to maximize impact in a short timeframe.
- VE 360 Workshops
• Brought together design, engineering, procurement, and operations in focused sessions to identify cost-reduction levers. - Lean Product Development
• Simplified product and equipment designs by removing non-value-added steps while maintaining performance standards. - Design Failure Modes and Effects Analysis (FMEA)
• Evaluated technical risks to ensure that cost reductions would not compromise quality, reliability, or manufacturability. - Stakeholder Mobilization
• Delivered quick, data-backed wins to overcome skepticism and build momentum for implementation. - Implementation Roadmap
• Developed a structured plan prioritizing CapEx reduction initiatives with clear technical and commercial justification for alignment and supplier negotiations.
Related Services
Manufacturing
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Facing Similar Capital Expenditure Challenges?
- Struggling to meet ambitious CapEx reduction targets in new technology investments.
- Seeking to align cross-functional teams around value engineering and lean design principles.
- Looking to uncover hidden savings while ensuring product reliability and manufacturability.
Discover More Clients Results
45K m²
Optimized factory layout (reduced from 52 Km²)
Industrial Manufacturing
Restarting a Greenfield Factory Planning Project
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 factory footprint
Aerospace & Defense
Designing a Future-Proof Drone Factory Through Modular Factory Planning
Design of a future-proof, modular drone factory enabling multi-product manufacturing, rapid scalability, and optimized investment for aerospace defence applications.
35%
Reduction in logistics headcount through automation
Food & Beverage
Enabling Efficient Greenfield Dairy Operations Through Production and Logistics Planning
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
Feasibility Study Enables +10,000 Pallet Pharma Distribution Center in Romania
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
A Competitive Award as the Catalyst for Global Factory Excellence at a global Automotive OEM
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
Co-creating the Industrial Future with Lean in a Refinery for a Leading Global Oil Company
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
Empowering Cost Transparency for High-Volume Battery Module Supply
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
Operational Excellence and Digital Transformation in Pharmaceutical Production
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.