45
Manufacturing sites
An OpEx Program for a Cosmetics Company Delivers +15% in OEE
A global beauty and cosmetics leader partnered with EFESO to accelerate its operational excellence journey and embed a continuous improvement culture across its global manufacturing network.
By deploying a structured WCOM/TPM program and implementing digital daily performance systems, the company achieved a +15% increase in OEE within two years, while strengthening cross-functional teamwork and analytical capabilities.
Life Sciences
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Our Client
The client is a global leader in the cosmetics and beauty industry, with a vast industrial and R&D footprint encompassing 45 manufacturing sites and 18 research centers worldwide. Employing over 77,000 people across more than 150 nationalities, the company drives innovation and excellence to deliver a diverse portfolio of beauty products to consumers around the globe.
+70K
Employees
€20B+
Annual turnover
The Challenge
The client needed to promote World Class Manufacturing and Total Productive Maintenance (TPM) as a way of life across all its global production sites. The key objective was to drive a continuous improvement culture centered on standardization and daily performance control to improve efficiency and competitiveness in a volatile demand environment.
Key challenges included:
- Low OEE performance caused by frequent breakdowns, short stops, and quality losses on packaging lines
- Lack of standardization and consistent use of daily performance systems across sites
- Need to strengthen cross-functional collaboration between production and maintenance teams
Real Results Achieved Together
The program delivered substantial improvements in efficiency and performance management, while embedding a strong cross-functional culture within the production organization. The initiative not only improved OEE performance but also drove a cultural shift towards proactive problem-solving and shared accountability across production and maintenance teams.
+15%
OEE increase
Transformation Impact
- Loss deployment identified and addressed in breakdowns, short stops, and quality issues
- Digital Daily Performance Meetings implemented in production and maintenance
- New standardized PM and PCS practices across all factories
- Strengthened cross-functional collaboration and analytical skills
Our Approach
EFESO supported the client and the Operations Director in deploying a structured, data-driven program focused on efficiency improvement, standardization, and cultural change.
Key steps included:
- Pilot Phase: Deep loss intelligence analysis to identify key loss areas on packaging, labeling, and capping machines at the pilot factory.
- Performance Control System (PCS): Development and implementation of a daily performance control system integrating production and maintenance.
- Standardization: Creation of standard preventive maintenance (PM) routines and PCS practices to ensure consistency across departments.
- Global Roll-out: Deployment of the pilot approach across all factories within the group to scale results and sustain improvements.
Related Services
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Ready to Transform Your Manufacturing Excellence?
- Achieve world-class operational performance across all your production sites
- Stop struggling with inconsistent efficiency and fragmented improvement initiatives
- Join leading manufacturers who have embedded continuous improvement as a way of life
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