+20K
Employees worldwide
Achieving World-Class Operations at Global Coffee Manufacturer
A leading pure-play coffee and tea company faced the challenge of harmonizing multiple continuous improvement cultures following major integrations. Working alongside the company’s own team, we deployed a manufacturing operating system across its global network, transforming operations at scale. This multi-year partnership established operational discipline and capability building as the foundation for sustained performance improvement.
Industry: Food & Beverage
Industry: Private Equity
Service: Leadership & Change Management
Service: Manufacturing
Service: Operational Excellence
Service: People and Organization
Our Client
A global pure-play coffee and tea company, that maintains a worldwide manufacturing footprint. Following a merger, the company needed to unify multiple operational cultures under one consistent way of working. The renewed focus on cost and cash management drives continuous operational improvements across its entire production network.
+100
Markets served globally
18
Manufacturing sites transformed
10
Customized operational pillars
“EFESO brought together first-class international experts from different countries—an approach that sets them apart from other consultancy firms that are more multilocal than multinational.
“
The Challenge
The company’s manufacturing footprint had recently integrated multiple companies, each bringing different continuous improvement cultures and methodologies. The organization needed to establish one unified way of working while facing several operational pressures:
- Cultural integration complexity: Multiple continuous improvement cultures required harmonization into a single manufacturing operating system that could drive consistent performance across all sites
- Pure-play market pressure: As a company focused solely on coffee and tea, it faced unique challenges from rising green coffee prices—without the portfolio diversification available to competitors. This required exceptional operational efficiency to maintain competitiveness
- Capability over quick wins: The organization prioritized building sustainable operational capabilities and preventive thinking resulting in cost savings step by step. The required a fundamentally different implementation approach focused on long-term culture change and shop floor ownership
Real Results Achieved Together
The partnership with EFESO transformed the company’s global manufacturing operations through systematic capability building and operational discipline. Working alongside local teams, we established a robust manufacturing operating system that delivered measurable improvements while building internal expertise for continuous advancement.
+50%
TIR rates improvement per year
-40%
Conversion costs reduction
+12%
OEE improvement in Processing
+11%
OEE improvement in Packaging
Transformation Impact
- Established predictability in daily and weekly production output across the global network
- Built a culture of pride and performance with zero-loss thinking embedded at shop floor level
- Developed internal World Class Office Management approach with global pillar leads managing continuous improvement independently
Our Approach
The partnership began with the immediate implementation of ten customized pillars tailored specifically for the company’s manufacturing operating system. We worked at two levels simultaneously—centrally developing manufacturing methodologies, training materials and assessment systems while supporting local implementation at individual sites.
The program structure featured four progressive phases, with stringent criteria governing advancement between phases. Each site had to demonstrate specific operational performance levels including TIR below 0.4, OEE above 70% and customer service levels exceeding 98.5% to progress.
We co-assessed sites alongside the company’s teams for two years, transferring assessment capabilities while ensuring consistent standards. The approach emphasized shop floor ownership from the foundation phase, requiring local leads to articulate and own the manufacturing program.
Following the initial manufacturing success, we expanded support to labor productivity improvements and supply chain optimization, adapting our partnership to the company’s evolving needs.
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Facing Similar Manufacturing Integration Challenges?
- Struggling to harmonize different operational cultures after mergers or acquisitions
- Building sustainable continuous improvement capabilities beyond quick cost wins
- Partnering with EFESO means transforming operations through proven methodologies and knowledge transfer
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