$35B
Annual revenue
Industry 4.0 Assessment Guides 50+ Smart Factory Projects in Medical Devices
A leading global pharmaceutical and medical devices company leveraged EFESO’s Industry 4.0 assessment to identify high-impact smart factory initiatives. More than 50 projects were launched, enabling predictive maintenance, digital shop floor management, and material flow automation with strong business cases and rapid payback.
Life Sciences
Digital & Ai
Manufacturing
Our Client
Our client is a major multinational corporation in the pharmaceutical and medical devices industry, boasting a remarkable revenue of 35 billion euros and a workforce of over 100,000 employees. With a global presence and a diverse portfolio of products.
+100K
Employees
The Challenge
- Assess Industry 4.0 potential across multiple sites
- Identify, pilot, and roll out initiatives to achieve targeted productivity
- Improvements of 10% per year
Real Results Achieved Together
Thanks to the Industry 4.0 assessment, more than 50 projects were launched, enabling predictive maintenance, digital shop floor management, and material flow automation with strong business cases and rapid payback.
+50
Smart Factory projects with positive business case
-2
Years in average payback period
Transformation Impact
- Conducted business case calculations, including project prioritization and cost-benefit analysis
- Developed a detailed implementation roadmap for Industry 4.0 projects in three waves, including work packages, resources, and budget
- Focus areas included smart material flow automation, predictive maintenance, and digital shop floor management
Our Approach
Potential analysis and short list of I4.0 opportunities
-
- Conducted 3-day site assessments focusing on material flow, quality and maintenance
- Provided an overview of process execution, information flow, IT systems and areas for improvement
- Collaboratively identified the most promising I4.0 initiatives, emphasizing smart material flow automation, predictive maintenance and digital shop floor management
Business case calculation
-
- Evaluation of investment costs, savings, complexity, technical feasibility and implementation effort to prioritize initiatives
Implementation roadmap
-
- Determination of a detailed roadmap to implement Industry 4.0 projects in 3 waves, including work packages, required resources and budget for first wave
Related Services
Digital investments fail to deliver operational impact. We translate technology into performance gains through practical AI deployment, data-driven decision systems, and frontline digital tools.
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Ready to Unlock Your Smart Factory Potential?
- Transform your operations with Industry 4.0 initiatives that deliver measurable productivity gains
- Stop guessing which digital projects will actually drive ROI
- Join leading manufacturers who’ve turned technology assessments into profitable transformation roadmaps
Discover More Clients Results
45K m²
Optimized factory layout (reduced from 52K m²)
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.
13%
Reduction in release time for high-value APIs
Chemicals
Life Sciences
A QC lab optimization framework helps a multinational chemical-pharmaceutical company achieved simultaneous gains in productivity, service level, and resource efficiency, delivering measurable improvements in release time, productivity, and FTE requirements without compromising quality.
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.
Industrial Manufacturing
Fact-based restructuring of a complex industrial site, enabling a clear shutdown decision, cash-drain elimination, and a structured roadmap for execution.
40%
Reduction in Capital Expenditures for new production technology
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.
+30%
OTIF improvement
Life Sciences
Reengineered Order Management processes for pharma services provider, achieving 30% OTIF improvement to 95% target.
-50%
Reduction in claims
Packaging
Global packaging manufacturer deploys WCOM™ across 24 plants, slashing claims and waste 50% while boosting productivity 30%.