+4K
Eemployees in manufacturing
Predictive Maintenance Implemented from Business Case to Full Roll-Out
Facing rising maintenance costs and aging equipment across its network, a global feed ingredients leader sought to evaluate and implement Predictive Maintenance as a lever to reduce expenses and improve equipment reliability.
Food & Beverage
Industrial Manufacturing
Digital & Ai
Operational Excellence
Our Client
Our Client is a long-standing leader in the feed ingredients market, with more than 4,000 people working in production across 12 locations. All plants operate using similar production processes, enabling strong replication potential for new digital methodologies such as Predictive Maintenance.
12
Production locations globally
The Challenge
With growing market saturation and increasing pressure to reduce operating expenses, the company identified maintenance costs as a strategic priority. After years of relying on outsourced maintenance, costs remained one of the organization’s largest budget items. Additional complexity included:
- Aging assets: Equipment installed decades ago required high and variable maintenance effort.
- Inconsistent usage intensity: Asset loads varied significantly across sites.
- Reactive maintenance burden: High urgency levels and unplanned interventions created inefficiencies and downtime.
- Preventive maintenance overuse: Preventive tasks were often performed on machines still in good condition.
- Limited internal digital capability: The company lacked both a PdM methodology and the skills to roll it out globally.
The goal was to determine whether Predictive Maintenance could reduce costs, increase reliability and availability, and provide a scalable model to be deployed across 12 sites—supported by new internal competencies and a vendor-independent approach.
Real Results Achieved Together
EFESO successfully guided the client through the complete predictive maintenance journey, from initial feasibility to full-scale implementation. The project delivered measurable improvements in maintenance efficiency and established a sustainable foundation for ongoing optimization across all production sites.
15%
Reduction in influenceable maintenance costs
-70%
Roll-out cost reduction
90%
Accuracy achieved in initial business case estimate, validating the feasibility study approach
Transformation Impact
- Successfully integrated predictive maintenance solution into existing IT landscape and maintenance workflows
- Built internal capabilities enabling the client to independently execute global rollout across 12 sites
- Established vendor-independent solution concept with seamless integration into daily operations
- Completed comprehensive RFI/RFP process leading to optimal in-house solution selection
Our Approach
EFESO partnered with the client across the full PdM lifecycle—from feasibility assessment to solution design, proof-of-value, and global scale-up preparation:
1. Feasibility Study (2 Weeks)
EFESO assessed equipment criticality, data availability, and resource readiness.
A first business-case estimate was delivered within two weeks and later proved 90% accurate.
2. Joint Solution Concept
Working with IT and maintenance teams, EFESO co-developed a PdM concept fully integrated into the company’s IT landscape and daily maintenance routines.
3. Progressive Asset Integration
Assets were gradually connected to the PdM strategy, expanding system coverage and preparing teams for future scale-up.
4. Multi-Month Proof of Value
The pilot validated tangible benefits, refined functional requirements, and prepared specifications for the final technical solution.
5. Vendor Review and RFI/RFP
EFESO supported vendor evaluation for a global rollout.
Ultimately, the client selected an in-house solution based on the validated proof-of-value.
6. Global Business Case and Rollout Blueprint
A comprehensive business case was developed for both the Spanish pilot plant and the future 12-site deployment.
The project not only delivered results—it built the internal capability and confidence needed for long-term PdM success.
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.
Ready to Transform Maintenance from Cost Center to Strategic Advantage?
- Unlock hidden value in your existing assets with data-driven maintenance strategies
- Stop wasting resources on reactive fixes and unnecessary preventive work
- Join industry leaders who've built sustainable capabilities for continuous improvement
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