+€10B
Annual revenues
New Maintenance Organization Delivers €260K/Y in Chemicals
A specialty polymers site within a global chemical company partnered with EFESO to redesign and implement a new maintenance organization. The goal: increase efficiency, improve Work Order processes, embed a culture of continuous improvement, and deliver €2.1M in benefits over three years.
Chemicals
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Our Client
The Specialty Polymers site of a major chemical company generating more than €10 billion in revenue and over €2 billion in EBITDA, highlighting strong financial stability and solid competitive positioning within the industry.
+€2B
EBITDA
The Challenge
- Design, review and implement a new functional organization in the Maintenance department
- Increase efficiency via a structured methodology to manage Work Order Process and maintenance activities
- Bottom line benefits objective of 2.1M€ in three years
Real Results Achieved Together
The transformation delivered measurable financial and organizational impact, strengthening maintenance performance and operational efficiency across the site.
€260K
Annual benefits achieved
100
Employees aligned under new maintenance structure
3
Maintenance areas fully redesigned and implemented
Transformation Impact
- New organizational structure, roles, responsibilities, KPI framework, and meeting cascade implemented across all three maintenance areas
- PCS tools and methodologies installed, validated, and coached daily
- Significant cost savings achieved through operational efficiency improvements and contractor renegotiations
- Strong local ownership enabled through change-agent coaching and empowerment
Our Approach
- Review and enhance the internal Maintenance Excellence methodology, aligning it with local current and future organization
- Define and validate the 1.5-year tactical implementation plan, generating local buy in and empowering local change agents
- Manage and coordinate the critical ramp up phase of implementation, providing coaching to maintenance team and to change agents (coach-the-coach approach)
- Support site management team in developing and embedding the required continuous improvement culture, and coach its use and dissemination
Related Services
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Ready to Transform Your Maintenance Operations Into a Strategic Asset?
- Unlock hidden capacity and reduce costs through optimized maintenance excellence
- Stop losing value to inefficient processes and outdated organizational structures
- Join chemical industry leaders who've achieved sustainable operational transformation
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.
+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.
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.