1.4K
Employees
Boosting Maintenance Efficiency and Reliability Across a PVC Production Network
A leading PVC manufacturer faced aging assets, declining reliability, and rising maintenance costs across several sites. EFESO conducted a rapid maintenance and reliability assessment, followed by in-depth operational analysis. The engagement identified over €2M in savings, uncovered major efficiency gains, and provided a detailed roadmap to strengthen preventive maintenance and boost production reliability.
Industry: Chemicals
Service: Manufacturing
Service: Operational Excellence
Service: Operations Strategy and Transformation
Our Client
Our client is a chemical company and the second-largest producer of PVC (Polyvinyl Chloride) in Europe. The group employs 1,400 people and generates a turnover of around 1.2 billion euros. Its activities are primarily located in France, reflecting a strong national presence in the industry.
€1.2B
Annual turnover
#2
Largest PVC producer in Europe
The Challenge
The company needed to significantly improve maintenance efficiency and recover reliability after years of underinvestment. Key objectives included:
- Assessing maintenance and reliability performance across four sites
- Identifying structural gaps and improvement levers
- Aligning stakeholders from shop floor to top management
- Building efficiency now to prepare for increasing demand
- Reducing technical production losses and optimizing preventive maintenance
Real Results Achieved Together
The assessment uncovered major savings opportunities and significant reliability gains across all sites.
Maintenance efficiency:
- Site 1: 20–25% FTE efficiency gain → €1–2M savings
- Site 2: 12–15% internal and 15–17% subcontractor efficiency gains → €420–482K
- +34% improvement in work orders/FTE (Sector 1)
- +15% improvement in work orders/FTE (Sector 2)
Reliability improvements:
- Site 1: 30–55% reduction in technical production losses in key product lines
- Site 2: 35–48% loss reduction across two main lines
- Reliability diagnostics uncovered 43–57% loss reduction potential overall
OEE performance:
- Upstream line increased from 88% to 93% (+6%)
- Downstream line increased from 73% to 85% (+13%)
Quality gains:
- >80% acceptance rate at first-time reception of works
Roadmap delivered:
- Detailed, actionable roadmap for each workstream
- Alignment ensured with local teams, management, and leadership
- Pilots launched at 2 sites, expanded to a 3rd, with a 4th in preparation
33 - 55%
Loss reduction
Transformation Impact
- More than two millions of euros in savings identified across sites
- An efficiency gain of thirty-four percent in Sector 1
- More than thirteen of OEE increase on downstream site
Our Approach
The engagement followed a structured, two-phase assessment complemented by implementation pilots.
Phase 1 — Rapid Assessment
- Identification of value creation levers
- High-level roadmap and opportunity mapping
- Support for “go / no-go” decisions on improvement initiatives
Phase 2 — In-Depth Operational Analysis
- Quantification of savings and efficiency opportunities
- Strategic alignment with leadership teams
- Detailed roadmap creation per workstream (maintenance, reliability, planning, scheduling, routines)
4 Core Levers Applied
- Preparation: improved processes, spares management, job cards, workshop pre-work
- Planning & Scheduling: weekly steering, workload-based planning, prioritization, critical path management
- Work Authorization: better coordination, reduced waiting times, improved anomaly tracking
- Performance Routines: clarified KPIs, roles, and responsibilities
Roll-out & Sustainability
- Pilots launched at two sites, expanded to a third, with deployment planned for a fourth
- KPI management and knowledge transfer routines established
- Structured leadership training and daily management practices introduced
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Ready to Strengthen Maintenance and Reliability Performance?
- Uuncover hidden efficiency opportunities in your maintenance organization
- Reduce technical losses and boost OEE
- A clear, actionable roadmap for multi-site deployment
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