+100
Countries of operation
Global Maintenance Excellence Delivers €50M+ Annualized Benefits
A world-leading specialty chemicals company aimed to harmonize maintenance operations and strengthen collaboration across its Technical Service and Business teams. EFESO implemented a Maintenance Excellence program to ensure long-term sustainability.
Chemicals
Manufacturing
Operations Strategy and Transformation
People and Organization
Our Client
A global specialty chemicals leader operating in over 100 countries with more than 33,000 employees. The company provides specialty chemical solutions across multiple industries worldwide.
+33K
Employees worldwide
The Challenge
The client faced several critical challenges:
- Harmonization of maintenance: Need to standardize maintenance practices across the 17 largest sites in the network
- Strengthening the ONE TEAM mindset: Improve collaboration between Technical Service and Business teams
- Sustainable transformation: Implement autonomous infrastructure to ensure continuous improvement
- Asset reliability and cost management: Drive improvements in maintenance efficiency and reduce overall spend
Real Results Achieved Together
EFESO’s program delivered measurable financial benefits while embedding a culture of operational excellence and collaboration across the client’s maintenance function.
20-25%
Efficiency gain on FTEs
30-55%
Reduction in technical production losses
+€50M
Annualized benefits achieved
Transformation Impact
Maintenance:
- Estimated efficiency gain for site 1: 20-25% on FTEs → €1-2M (to be negotiated with sub-contractors)
- Estimated efficiency gain for site 2: 12-15% (internal) 15-17% (subcontractor) → €420-482K
Reliability:
- Site 1: Estimated reduction of the technical production losses by 30-40% (product 1) and 40-55% (product 2)
- Site 2: Estimated reduction of the technical production losses by 35-47% (line 1) and 40-48% (line 2)
Our Approach
1st step, Rapid Assessment on two sites. The objectives were:
- To assess value creation levers
- To identify key opportunities & high-level roadmap
- To support go/no go decision for operations improvements
2nd step, Operations Analysis on two sites. The objectives were:
- To determine and quantify opportunities (business case)
- To align strategy with top and middle management
- To detail the roadmap by workstream
The next step would be to implement the defined roadmap on the two sites where the operations’ analysis was made.
Related Services
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Workforce transformation, leadership development, and structure optimization. Learn more about our People & Organization consulting services.
Ready to unlock hidden value in your maintenance operations?
- Transform maintenance from a cost center to a competitive advantage
- Stop losing millions to unplanned downtime and inefficient processes
- Join global leaders who've achieved sustainable operational excellence
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