+10K
Employees globally
Harmonizing Processes and Implementing Enterprise-Wide Standard Work for a Chemical Manufacturer
A global specialty chemicals leader was facing significant cost and reliability challenges in operations. Their sites operated differently, there was no global playbook to Operate, Improve and Maintain plant operations. Disparate work processes were dated, or non- existent and site headcount had significantly grown overtime due to inefficiencies. In collaboration with EFESO, the company standardized and harmonized operations work processes and organizational structures through-out the enterprise which significantly reduced cost. The transformation touched facilities across continents, establishing consistent operating processes and organizational models while preserving critical institutional knowledge.
Chemicals
Cost and Value Engineering
Manufacturing
Operations Strategy and Transformation
People and Organization
Sustainability
Our Client
This global specialty chemical and performance materials company operates several distinct business units. With a century-long history of acquisitions, the company maintains operations across all continents through diverse manufacturing facilities that range in size and technological complexity.
+100
Facilities worldwide
>$10B
Annual revenue
+10
Sites in initial scope
The Challenge
The organization faced critical operational inconsistencies that threatened productivity and cost-competitiveness. Key challenges included:
- Disparate work processes – Operations varied significantly between businesses, countries and even units within larger sites. No standard organizational model existed to define consistent roles and responsibilities, making it difficult to justify costs and achieve uniformity in leadership structures
- Aging workforce and knowledge loss – Rising attrition, particularly in the United States where retirement structures had changed, led to long-term employees departing without documenting their expertise. This institutional knowledge gap threatened business continuity and operational excellence
- Acquisition complexity – Multiple acquisitions over the company’s long history resulted in increased operational complexity. Different plants operated with inconsistent management structures – some with very lean management and others with many layers, creating inefficiencies across the globe
Real Results Achieved Together
The partnership delivered comprehensive operational transformation through global process harmonization and organizational restructuring. Working across multiple continents, teams implemented standardized work processes that fundamentally changed how plants operate, maintain equipment and ensure quality within the 2 years of project implementation.
$25M
Cost reduction through organizational optimization
15%
Capacity increase unlocked
$12M
NCM reduction & disposal cost avoidance
Transformation Impact
- Accelerated implementation, leveraging best practice templates across all sites
- Comprehensive documentation that preserved institutional knowledge
- Sustainable operational improvements through train-the-trainer model
Our Approach
EFESO worked closely with the client’s global leadership team to develop and implement standard work, supported by robust change management. The engagement began with an assessment focusing on operations, maintenance, reliability, quality and process improvement.
Working through collaborative workshops with representatives from twelve sites, teams built a comprehensive standard work process framework that could be adapted to accommodate different business arms and site-specific nuances. The approach included developing streamlined, role-based organizational models that de-layered structures while providing clear responsibilities and accountability.
Implementation involved a train-the-trainer model, providing detailed training to selected individuals who then cascaded knowledge throughout their sites. This included exercises to identify gaps in current processes and develop operational transformation plans. Teams created extensive training documentation including PowerPoint presentations, one-point lessons and gallery walks, ensuring comprehensive knowledge transfer. A program management office provided oversight and governance to implement the new ways of working across multiple global sites.
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Facing Similar Operational Standardization Challenges?
- Struggling with inconsistent processes across multiple sites and regions
- Seeking to capture institutional knowledge before workforce transitions
- Ready to transform complexity into standardized operational excellence
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