12
sites worldwide
Driving Operational Excellence Across 12 Global Chemicals Sites
A global specialty chemicals producer faced integration challenges after multiple acquisitions. EFESO implemented a tailored Operational Excellence harmonizing ways of working, creating a common production system, and training over 2,500 employees.
Chemicals
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Our Client
A global specialty chemicals producer operating 12 sites across the Americas, EMEA, and APAC, with a history of growth through acquisitions. The company combines strong international presence with extensive operational capabilities in manufacturing specialty chemical products.
“I really appreciate the way of collaboration with EFESO – it really feels we are working as one team. We have been able to realize substantial benefits and developed our internal capability.
“
The Challenge
Following acquisitions and organizational changes, the client needed to:
- Integrate heritage organizations: Harmonize two distinct cultures and ways of working across all sites
- Improve profitability: Deliver both short-term results and increase long-term organizational maturity
- Establish a common production system: Facilitate site integration, knowledge exchange, and a unified Operational Excellence approach
- Harmonize Maintenance & Manufacturing: Standardize and professionalize work practices
- Create sustainable infrastructure: Embed continuous improvement capabilities across all operations
- Deliver substantial financial impact: Original ambition of ~€40M recurring annual EBITDA
Real Results Achieved Together
EFESO guided the client through a multi-site Operational Excellence program, achieving measurable financial benefits while fostering a cohesive and skilled operations community.
€67M
annual benefits achieved
450
individuals trained in OPEX topics
€120M
value potential identified
Transformation Impact
- Developed a client-specific production system across 12 sites
- Trained individuals to lead Operational Excellence initiatives, with broader training reaching 2,570+ employees
- Delivered 26% fixed cost reduction, 8% variable cost improvement, and 66% additional margin potential
- Created sustainable infrastructure including Autonomous Management, Focused Improvements, and Planned Maintenance pillars
- Built communities of practice to facilitate collaboration and continuous improvement across all sites
Our Approach
EFESO implemented a structured, phased methodology:
- Global scans: Assess 12 sites to validate benefits and identify quick wins
- Site-specific roadmaps: Develop customized plans for Operational Excellence deployment
- Client-specific production system: Design and roll out to all sites
- Organizational blueprint for maintenance: Standardize roles and processes globally
- BOOST, BUILD, Continuous Improvement: Pilot wave sites, then scale to remaining operations
- Pillar structure implementation: Establish Autonomous Management, Focused Improvements, and Planned Maintenance with trained Process Kaizen Engineers
- Capability building: Hands-on coaching and structured training programs for hundreds of employees
This approach ensured rapid value realization while embedding a unified culture of Operational Excellence.
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 Global Operations Into a Unified Excellence Engine?
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- Stop struggling with fragmented systems and inconsistent performance across your sites
- Join global leaders who've built world-class production systems that deliver year after year
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