+€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.
Consumer Goods and Luxury
Logistics and Distribution
Manufacturing
Operations Strategy and Transformation
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
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
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
+25
Business cases initially identified
Consumer Goods and Luxury
Design and implementation of a 10-year strategy targeting 4% annual growth for a world-leading luxury group, focused on aligning operations.
12
"Golden Rules" implemented for production planning
Industrial Manufacturing
Creating a solid, structured plan for the material flow of its production and validated the static forecast, enabling the factory to increase the output with the existing machinery.
+10K
Pallet positions created through optimized DC layout expansion design
Life Sciences
EFESO conducted a feasibility study for a new 10,000-pallet automated warehouse in Romania, optimizing logistics design, layout, and CAPEX to enable scalable, efficient pharmaceutical distribution.
40%
Reduction in Capital Expenditures for new production technology
Aerospace & Defense
Packaging
A leading global manufacturer of glass containers reduce capital expenditure by 40% in the commercialization of a new glass production technology by applying Value Engineering and Lean Product Development principles.
+10-36%
Productivity and capacity increases
Life Sciences
Implemented Lean practices across 40+ pharmaceutical labs, achieving 30% average productivity gains and 70% improvement in on-time batch releases.
30%
Reduction in unplanned stops
Consumer Goods and Luxury
Life Sciences
Redesigned operational excellence across 23 plants, unifying fragmented practices and internalizing production for global consumer health company.
$3.87M
Annual cost reduction vs. baseline
Chemicals
Network redesign delivered $3.87M savings, offsetting raw material cost increases while enabling international expansion.
2X
Profit doubled in 18 months
Food & Beverage
Food manufacturer doubled profits from £45M to £90M through 16-site operational transformation and capability building.