5
Commercial branches in Europe
Leveraging Digital Twin for Production Capacity Optimization
A global leader in home and garden manufacturing sought to optimize production capacity without new investments. Partnering with EFESO, the company implemented a Digital Twin solution, improving efficiency by 16.3%, reducing production planning time by 2 hours per day, and avoiding a €500K investment in new equipment.
Industry: Consumer Goods and Luxury
Service: Digital & Ai
Service: Supply Chain
Our Client
A global leader in home and garden manufacturing, offering a diversified portfolio of plant pots and related products, supported by multiple international production sites and commercial branches.
The Challenge
The company faced a sudden surge in demand and needed to increase production capacity without significant investment. Key challenges included:
- Demand increase of more than 30%, prompting consideration of additional equipment.
- High production planning complexity due to multiple SKUs, constraints, and varying machine capabilities.
- Heavy reliance on the Production Planning manager’s experience for achieving satisfactory results.
Real Results Achieved Together
The implementation of a Digital Twin for production optimization allowed the client to unlock existing capacity, streamline planning, and make data-driven decisions without new equipment.
+16.3%
Production efficiency improvement
-2
Hours/day needed for production planning
Transformation Impact
- Increased understanding of optimal production capacity and bottlenecks
- Streamlined production planning and scheduling with a user-friendly digital tool
- Optimized machine assignment and throughput using a Digital Twin simulation
- Digitally validated potential equipment additions before committing CapEx
- Improved operational visibility to make informed capacity decisions
Our Approach
EFESO deployed a Digital Twin methodology to optimize production capacity:
- Digital Twin Modeling
- Studied the current production process and constraints
- Evaluated capacity across different configurations
- Optimization Engine for Scheduling
- Maximized throughput by creating a scheduling and machine assignment optimization engine
- Tool and Dashboard Implementation
- Delivered a user-friendly tool for ongoing planning
- Created a dashboard to visualize production status at each step
- Investment Validation
- Digitally quantified the impact of potential new equipment before committing real capital
Related Services
Digital & AI
Digital investments fail to deliver operational impact. We translate technology into performance gains through practical AI deployment, data-driven decision systems, and frontline digital tools.
Supply Chain
Supplier complexity obscures 70% of your value creation. We strengthen networks through supplier development programs, risk mitigation strategies, and collaborative innovation platforms.
Facing Similar Production Capacity Challenges?
- Managing multiple SKUs and complex production constraints
- Looking to increase capacity without significant CapEx
- Wanting data-driven, digitally validated solutions to optimize throughput and planning
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