€1B
Annual revenue
Global Apparel Retailer Saves €15.5M in 18-Month Turnaround
A global apparel retailer faced challenges in time-to-market, service levels, and industrial costs. EFESO led an 18-month transformation program across four countries, reducing order rejections from 20% to 8%, and streamlining product complexity.
Industry: Retail
Service: Cost and Value Engineering
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: Supply Chain
Our Client
A leading global apparel retailer generating €1 billion in revenue, employing over 7,000 people, and operating in multiple countries across Europe and North Africa. The client focuses on manufacturing and delivering clothing and textile products worldwide.
+7K
Employees
4
Countries included in the program (Italy, Croatia, Serbia, Tunisia)
The Challenge
The client aimed to turn its industrial property chain into a strategic advantage while improving market responsiveness and cost efficiency:
- Time-to-market delays: Extended production lead times were reducing competitiveness
- High industrial costs: Operational expenses and complexity were eroding profit margins
- Service and quality issues: Low service level (78%) and high order rejection rate (20%) impacted customer satisfaction
- Complex product portfolio: Large variety of fabrics and colors increased production complexity and reduced flexibility
Real Results Achieved Together
Through a structured 18-month Operational Excellence program, EFESO helped the client improve service, quality, and cost performance while reducing complexity and enhancing competitiveness.
€15.5M
Savings delivered (OpEx + right sizing)
+10%
Service level improvement
-60%
Reduction in order rejections
Transformation Impact
- Improved speed and punctuality: service level increased from 78% to 88%
- Enhanced quality control: order rejection rate reduced from 20% to 8%
- Increased flexibility: reduced product complexity with 30% fewer fabrics and 60% fewer colors
- Cost competitiveness: achieved €15.5M savings (6.5M OpEx, 8.5M right sizing), reducing industrial costs by 8%
Our Approach
EFESO executed a two-phase program: assessment (6 months) and implementation (18 months), focusing on the manufacturing company of the group. The methodology included:
- Establish agile and lean organizations aligned with defined processes
- Foster exceptional performance in internal departments and external laboratories
- Streamline Product Complexity and Simplify Industrialization process to reduce time-to-market
- Ensure superior service levels and reduce production lead times
Related Services
Cost and Value Engineering
Rising costs demand optimization from design through production. We apply cross-functional value engineering, zero-based redesign, and continuous cost tracking to protect margins.
Manufacturing
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Operations Strategy and Transformation
Helping organizations rethink how they create value. We strengthen performance, build resilience, and accelerate growth across every layer of your business.
Supply Chain
Supplier complexity obscures 70% of your value creation. We strengthen networks through supplier development programs, risk mitigation strategies, and collaborative innovation platforms.
Ready to Transform Your Supply Chain Into a Competitive Advantage?
- Turn operational complexity into streamlined efficiency that responds to market demands in real time
- Stop watching profit margins erode while competitors move faster
- Join leading retailers who've unlocked millions in savings while improving service levels
Discover More Clients Results
+16.3%
Production efficiency improvement
Consumer Goods and Luxury
Leveraging Digital Twin for Production Capacity Optimization
A global leader in home and garden manufacturing looking to optimize production capacity without new investments.
Up to 20%
Packaging cost reduction across multiple SKUs
Consumer Goods and Luxury
Driving Packaging and Packing Cost Savings through Cost Engineering
A major international toy manufacturer looking to optimize packaging and outsourced packing costs.
8%
EBITDA increase through improved operational productivity
Consumer Goods and Luxury
Increasing Operational Productivity to Drive EBITDA Growth in Fashion and Leather Goods
A global luxury fashion house aimed to improve operational productivity and achieve target EBITDA despite complex production challenges.
30%
Improvement in sales forecast accuracy through advanced analytics
Consumer Goods and Luxury
Improving Supply Chain Agility Through Advanced Forecasting and Digital Tools
A family-owned luxury jewelry designer and retailer seeking to improve supply chain agility to better support its private sales model.
75%
Reduction in systematic start-up issues and improved right-first-time performance
Consumer Goods and Luxury
Implementing Early Equipment Management to Improve Project Start-Up Performance
A global fast-moving consumer goods company sought to implement Early Equipment Management (EEM) across its operations to improve project execution and equipment start-up performance.
€8M
CapEx and OpEx savings over 3 years versus baseline scenario
Consumer Goods and Luxury
Industrial and Logistics Network Optimization for a Home Care Products Manufacturer
A leading European manufacturer of home care products sought to challenge and optimize its industrial and logistics footprint following strong external growth.
30%
Reduction in unplanned stops over 2 pilot lines
Consumer Goods and Luxury
A Program Implementation Achieves Transformational Improvements in Consumer Health Company
A global consumer health company implemented an operational transformation, delivering a 30% reduction in unplanned stops and validated standards for global rollout, supporting a shift to a proactive operational culture.
4
Legal-entity handbooks detailing processes, systems, and organizational structures at Level-3 detail
Consumer Goods and Luxury
Designing a Target Operating Model for a Growing Nutraceutical CDMO Group
Discover how EFESO helped defined a Target Operating Model (TOM) that improved governance and created the foundation for future ERP implementation.