80+
Countries
Full Production System Delivers €5M+ Savings in Pharma
A multinational Life Sciences company partnered with EFESO to strengthen and sustain its production system across two key manufacturing sites. Facing cost and efficiency pressure due to declining margins and unstable production performance, the company sought to achieve lasting operational excellence. Through a combination of leadership development, on-site coaching, and full production system deployment, EFESO enabled the client to stabilize operations, improve KPIs, and generate savings exceeding €5 million.
Life Sciences
Manufacturing
Operational Excellence
Our Client
A multinational Life Sciences company with operations in over 80 countries, employing more than 100,000 people worldwide. The company generates €47.6 billion in annual sales and invests €7.1 billion in R&D each year. This project covered two of its key manufacturing sites.
+100K
Employees
€47.6B
Sales
€7.1B
Investment in R&D
The Challenge
The client faced increasing cost and efficiency pressures due to decreasing margins and unsteady production performance. A previous attempt to implement a production system had not proven sustainable, resulting in high unplanned downtime, variability in changeover times, and product defects.
The challenge centered on:
- Re-establishing a sustainable and effective production system
- Stabilizing performance across formulation and packaging lines
- Embedding accountability and ownership on the shop floor through leadership development
Real Results Achieved Together
Through the successful deployment of the full production system, EFESO and the client achieved sustainable operational improvements and measurable financial results. By embedding servant leadership and a robust production system structure, the organization achieved sustained operational discipline and performance stability across its manufacturing network.
+€5M
Savings achieved
20
Formulation and packaging lines addressed
Transformation Impact
- Successfully addressed 20 formulation and packaging lines, resulting in substantial savings exceeding €5 million
- Achieved stabilization of operational processes and notable improvements in performance KPIs
- Facilitated a transition to servant leadership behavior, fostering true ownership and accountability on the shop floor
- Effectively integrated pillar teams into the organization, driving and sustaining the production system
Our Approach
- Implementation Approach
- Tailored training concept with practical exercises for operative leaders and operators
- Implementation support with daily presence on the shopfloor (we do you do)
- Ensuring methods usage through Process Confirmations & Daily Shopfloor Management
- Leadership Development
- Set-up of new Line Leadership structure
- Coaching to support leaders and to practice Servant Leadership culture on the shopfloor
- Pillar Organization
- Implementation of local pillar teams as owners and ambassadors of pillar methods
- Strategy deployment and alignment between site business targets and production system
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 Production System Into a Sustainable Competitive Advantage?
- Achieve operational excellence that sticks—not just another failed implementation
- Stop watching your margins shrink while production struggles with unplanned downtime and inconsistent performance
- Join multinational leaders who’ve built true ownership and accountability on their shop floor
Discover More Clients Results
+10K
Pallet positions created through optimized DC layout expansion design
Life Sciences
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.
-39%
Warehouse coverage reduction versus previous year average
Consumer Goods and Luxury
Mapped end-to-end jewelry supply chain, eliminated waste across suppliers, delivering 39% lower inventory coverage.
+€40M
Savings
Packaging
Deployed global OpEx program across 25 plants, standardizing waste reduction practices to deliver €40M savings and 4.5M tons CO₂ reduction.
+15%
OEE increase
Life Sciences
Deployed World Class Manufacturing pilot across cosmetics plants, driving OEE from 55% to 70% through standardization.
€90M
in Opportunities identified during the program
Chemicals
A global chemical company launched a joint performance improvement initiative with EFESO across twelve plants on four continents. Significant improvements in cost drivers and margins were achieved.
-15%
Reduction in indirect purchasing costs
Automotive and Commercial Vehicles
Private Equity
Industrial machinery manufacturer faced complexity in custom equipment production. We implemented modular design principles, standardized components, and optimized project management, reducing lead times by 40%.
€2.7B
Total savings achieved
Automotive and Commercial Vehicles
Automotive supplier needed profitability improvement for complex drive components. We established end-to-end value optimization, supplier collaboration, and cost engineering, improving margins across entire value chain.
8-10%
Transformation cost reduction achieved
Aerospace & Defense
Aerospace corporation faced fragmented digital infrastructure across divisions. We launched enterprise-wide transformation, integrated systems, and drove operational excellence, reducing operational costs by 10%.