+€330M
Annual turnover
Improving Time to Market While Minimizing Costs for a Specialized Sportswear Manufacturer
A specialized sportswear manufacturer faced mounting pressure from concentrated Asian supply chains and limited distribution flexibility. Working with EFESO, the company transformed its operations across three continents, establishing new distribution hubs and optimizing warehouse processes. This comprehensive operational overhaul delivered €965,000 in annual savings while dramatically improving market responsiveness.
Industry: Consumer Goods and Luxury
Service: Logistics and Distribution
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: Supply Chain
Our Client
This multinational leader designs and manufactures technical clothing, apparel, footwear and protection systems for motorsports and action sports. Operating with a hybrid distribution model combining direct drop shipment and stock-based fulfillment, the company manages operations across Europe, North America, Asia-Pacific and Latin America. Its product portfolio spans multiple categories requiring specialized manufacturing and distribution capabilities.
25K
SKUs managed yearly
+700
Employees worldwide
25K sqm
Main warehouse capacity
The Challenge
The company’s growth trajectory collided with operational constraints that threatened profitability and market expansion opportunities.
- Distribution network limitations: Made-in-Asia products stocked in Europe faced double duty charges when exported to APAC and Latin America markets, creating 4-6 week lead times and forcing customers to purchase from European stock despite higher prices and longer delivery times
- Warehouse inefficiency: The 25,000 sqm Italian hub struggled with 24,386 SKUs including 30% previous collection items, experiencing space shortages at picking locations, no clear SKU allocation strategy across manual and automated systems and a dependency on external warehousing which constituted 17% of direct costs
- eCommerce readiness gap: Previously operating solely in B2B markets, through distributors and dealers, the company lacked the operational setup necessary for a B2C channel launch. This required new processes for order fulfillment, returns management and omnichannel coordination, without disrupting existing B2B performance
Real Results Achieved Together
The transformation encompassed distribution network redesign, warehouse optimization and a successful eCommerce B2C launch. Working alongside internal teams, we implemented targeted improvements across the entire supply chain, from supplier management to last-mile delivery.
€965K
Annual warehouse cost reduction
-24%
Total warehousing costs
+45%
Assembly line productivity
Transformation Impact
- Established Singapore hub enabling duty-free B2B benefits through Free Trade Agreements
- Reduced headcount requirement from 91 to 73 FTEs through process optimization
- Launched fully operational eCommerce B2C channel with dedicated fulfillment processes
Our Approach
Working closely with the in-house team, we conducted comprehensive RFI, RFQ and expert interviews for 3PL selection across Vietnam, Malaysia and Singapore, evaluating market proximity, service costs and country regulations.
The warehouse transformation introduced double-capacity picking methods along with flexible shelf and bin storage systems for slow-movers. We also optimized forklift replenishment policies, reducing workload by half.
Together we implemented batch picking for ecommerce orders, designed dedicated packing stations with branded packaging and established quality control gates for returns processing. We also developed SKU allocation strategies based on rotation classes, separating high-runners for pallet picking, medium-runners for carton shelving and low-runners for single-piece management.
The implementation included MRP parameter adjustments, production sequencing tools and MES system installation for performance monitoring. Knowledge transfer occurred through visual management boards, KPI dashboards and structured management routines that bridged B2B and B2C operations.
Related Services
Manufacturing
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Operations Strategy and Transformation
Helping organizations rethink how they create value. We strengthen performance, build resilience, and accelerate growth across every layer of your business.
Supply Chain
Supplier complexity obscures 70% of your value creation. We strengthen networks through supplier development programs, risk mitigation strategies, and collaborative innovation platforms.
Facing Similar Supply Chain Complexity Challenges?
- Struggling with multi-continent distribution inefficiencies and rising logistics costs
- Seeing opportunities to optimize warehouse operations while launching new sales channels
- Ready to transform fragmented operations into integrated excellence with measurable impact
Discover More Clients Results
+16.3%
Production efficiency improvement
Consumer Goods and Luxury
Leveraging Digital Twin for Production Capacity Optimization
A global leader in home and garden manufacturing looking to optimize production capacity without new investments.
Up to 20%
Packaging cost reduction across multiple SKUs
Consumer Goods and Luxury
Driving Packaging and Packing Cost Savings through Cost Engineering
A major international toy manufacturer looking to optimize packaging and outsourced packing costs.
8%
EBITDA increase through improved operational productivity
Consumer Goods and Luxury
Increasing Operational Productivity to Drive EBITDA Growth in Fashion and Leather Goods
A global luxury fashion house aimed to improve operational productivity and achieve target EBITDA despite complex production challenges.
30%
Improvement in sales forecast accuracy through advanced analytics
Consumer Goods and Luxury
Improving Supply Chain Agility Through Advanced Forecasting and Digital Tools
A family-owned luxury jewelry designer and retailer seeking to improve supply chain agility to better support its private sales model.
€8M
CapEx and OpEx savings over 3 years versus baseline scenario
Consumer Goods and Luxury
Industrial and Logistics Network Optimization for a Home Care Products Manufacturer
A leading European manufacturer of home care products sought to challenge and optimize its industrial and logistics footprint following strong external growth.
30%
Reduction in unplanned stops over 2 pilot lines
Consumer Goods and Luxury
A Program Implementation Achieves Transformational Improvements in Consumer Health Company
A global consumer health company implemented an operational transformation, delivering a 30% reduction in unplanned stops and validated standards for global rollout, supporting a shift to a proactive operational culture.
4
Legal-entity handbooks detailing processes, systems, and organizational structures at Level-3 detail
Consumer Goods and Luxury
Designing a Target Operating Model for a Growing Nutraceutical CDMO Group
Discover how EFESO helped defined a Target Operating Model (TOM) that improved governance and created the foundation for future ERP implementation.
~10K m²
Optimized factory footprint
Aerospace & Defense
Designing a Future-Proof Drone Factory Through Modular Factory Planning
Design of a future-proof, modular drone factory enabling multi-product manufacturing, rapid scalability, and optimized investment for aerospace defence applications.