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.
Industry: Chemicals
Service: Manufacturing
Service: Operational Excellence
Service: 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.
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Ready to Transform Your Global Operations Into a Unified Excellence Engine?
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