+30
Countries
Global Opex Program Delivers €40M Savings and 4.5M Tons CO₂ Reduction
Our client is a multinational leader in packaging solutions, specializing in flexible, food and fiber packaging. With operations in more than 30 countries and over 100 manufacturing plants worldwide, generating €4.2 billion in net sales annually. Positioned as a global specialist, they face an increasingly competitive industry, with challenges ranging from high material losses and inconsistent site practices to a need for a continuous improvement culture. Despite a strong focus on cost management, they sought sustainable, capability-building solutions to ensure lasting impact and resilience.
Packaging
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Sustainability
Our Client
Our client is a multinational leader in packaging solutions, specializing in flexible, food and fiber packaging. With operations in more than 30 countries and over 100 manufacturing plants worldwide, generating €4.2 billion in net sales annually. Positioned as a global specialist, they face an increasingly competitive industry, with challenges ranging from high material losses and inconsistent site practices to a need for a continuous improvement culture.
+100
Manufacturing plants worldwide
€4.2B
Net sales annually
The Challenge
- High material loss compared to industry benchmark and material waste reduction forced by market downturn
- No standard way of working across sites
- No continuous improvement culture
- Difficulty in cost deployment approach adoption
- Difficulty in on-site delivery due to pandemic
- Very strong cost-focus, but struggling to give capability development the right priority, for securing sustainability of the savings
Real Results Achieved Together
Through a comprehensive five-year operational excellence program spanning 25 plants across 23 countries, EFESO helped transform the client's operations, delivering substantial financial savings while building lasting capabilities and driving significant environmental impact.
+€40M
Savings
+€200M
Losses identified
-4.5M
Tons CO₂ reduction
9K
People coached and trained
Transformation Impact
The initiative has delivered significant financial, environmental, and organizational benefits. It has strengthened the organization’s ability to identify and address inefficiencies, resulting in substantial savings and uncovering potential areas of loss. At the same time, it has made a meaningful contribution to sustainability by reducing waste and lowering carbon emissions. Beyond measurable outcomes, the program has cultivated a culture of continuous improvement, empowering teams across the organization, enhancing skills through coaching and training, and building internal expertise with certified trainers.
Our Approach
- Design and implementation of a bespoke Operational Excellence Program with tighter focus on material waste reduction in 25 plants, in 23 countries, over five years
- Global academy implementation with remote and on-site delivery coaching technologies
- Standard loss analysis approach supported by dashboarding, including operational and financial benefits planning and tracking capability development
- Robust program management following the roll out of cost deployment from the start
- Focused follow up and reporting governance
- Leadership development program
- Implementation of a global assessment system, including plant, pillar and team assessments
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Ready to Transform Waste into Lasting Value?
- Build a continuous improvement culture that delivers measurable financial and environmental impact
- Stop struggling with inconsistent practices and unsustainable cost-cutting across your global operations
- Join industry leaders who've turned operational excellence into competitive advantage
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