10%
CAGR in assembly labor productivity in participating plants
A Competitive Award as the Catalyst for Global Factory Excellence at a global Automotive OEM
A multinational automotive manufacturer sought to transform its global factory network into a hub of continuous improvement and innovation. EFESO co-created a competitive award program that delivered measurable productivity gains, cost reductions, and cultural transformation, creating a self-sustaining excellence network.
Industry: Automotive and Commercial Vehicles
Service: Leadership & Change Management
Service: Manufacturing
Service: Operational Excellence
Service: People and Organization
Our Client
A global automotive manufacturing company operating production plants on three continents, delivering high-performance components and assemblies for both internal vehicle brands and external OEMs. The client manages a complex, geographically diverse production network seeking modernization, sustainability, and global best-practice alignment.
The Challenge
The client faced growing operational and organizational pressures:
- Escalating cost pressures: Threatening profitability and competitiveness across the network
- Local silos of best practices: Innovations were not leveraged globally, causing missed synergies
- Lack of standardized performance benchmarks: Difficult to identify top-performing and underperforming plants
- Traditional improvement initiatives falling short: Limited engagement and sustainability of results
- Emerging priorities: Sustainability, digital transformation, and diversity were not fully embedded
- Motivation and recognition gaps: Teams felt disconnected from the company’s larger goals
Leadership aimed to inspire lasting change by establishing a program that combined measurement, recognition, and global collaboration.
Real Results Achieved Together
The award program delivered quantifiable operational, financial, and cultural impact across the global plant network.
>5%
CAGR improvement in OEE across network
+50%
Plants achieving above-benchmark scores in core dimensions
Transformation Impact
- Cost reductions and productivity improvements achieved through employee-driven initiatives and sharing best practices
- Extensive adoption of digitalization, automation, and smart factory pilots
- Employee motivation and engagement improved, with award-winning plants demonstrating higher pride and retention
- Top-performing plants mentored peers, accelerating the adoption of best practices across geographies
- ESG and diversity gains: e.g., energy savings of 15% and 30% increase in female management representation in awarded categories
- Annual award ceremony created visibility and reinforced strategic alignment, drawing senior executives including the CEO
- Transparent benchmarks and continuous evaluation fostered a culture of healthy competition and ongoing improvement
Our Approach
EFESO deployed a multi-phased program combining benchmarking, competition, recognition, and continuous evolution:
- Standardized Competitive Framework: Fact-based criteria for productivity, cost, flexibility, sustainability, and diversity created a “ranking league” to drive ambition and engagement.
- Comprehensive Assessment Process: On-site audits and digital submissions captured granular performance data. Monthly benchmarks ensured continuous engagement.
- Networking, Learning, and Recognition: Regular plant tours, webinars, workshops, and the annual “Oscar Night” celebrated top-performing sites, facilitating knowledge transfer and motivation.
- ESG and Continuous Evolution: Award categories evolved to include digitalization, diversity, and net-zero environment metrics alongside classic operational KPIs.
- Management Engagement and Communication: Transparent dashboards and executive sponsorship maintained visibility and strategic alignment.
- Best Practice Sharing and Peer Review: Finalists showcased projects internally, and top plants mentored newer entrants to raise performance.
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Seeking to Embed Sustainable Operational Excellence Globally?
- Looking to align global factory networks on common performance benchmarks
- Wanting to drive productivity, cost efficiency, and employee engagement simultaneously
- Planning to integrate sustainability, diversity, and digitalization into core operations
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