€15B
Annual turnover
A Program Implementation Achieves Transformational Improvements in Consumer Health Company
A global consumer health company implemented a 6-month operational transformation across pilot production lines; delivering a 30% reduction in unplanned stops, enhanced employee engagement, and validated standards for global rollout, supporting a shift to a proactive operational culture.
Industry: Consumer Goods and Luxury
Service: Manufacturing
Service: Operational Excellence
Our Client
A global consumer health company specializing in over-the-counter (OTC) products and wellness solutions, managing a broad portfolio of non-prescription medicines across multiple international markets.
23
Manufacturing plants over 4 countries
The Challenge
The newly formed consumer health company faced complex operational and cultural transformation requirements across its global manufacturing network:
- Fragmented operational approach: Inconsistent methodologies for maintenance and OEE measurement.
- Dependency on external production: Only 55–60% of production internalized.
- Cultural shift required: Transition from a highly regulated pharmaceutical environment to a consumer health operational culture.
Real Results Achieved Together
The company achieved operational improvements and cultural shifts that enhanced production reliability and employee engagement across pilot lines.
30%
Reduction in unplanned stops over 2 pilot lines
Transformation Impact
- Major operational improvements and cultural shifts achieved.
- Enhanced employee understanding of daily activities’ link to overall business performance.
- Leadership aligned and committed to operational excellence as a strategic priority.
- Pilot program validated standards for replication across remaining plants and regions.
Our Approach
EFESO delivered the transformation through three integrated blocks:
- Redesign of the Operational Excellence Program
- Developed a structured program tailored to the company’s consumer health environment.
- Targeted Training Across Organizational Levels
- Delivered training from shop floor teams to global leadership and pillar owners.
- Pilot Implementation and Standard Validation
- Implemented the program in a lead site.
-
- Developed and validated operational standards through daily direction setting and run-on-target systems.
- Throughout implementation, EFESO ensured continuous alignment with internal stakeholders, building on existing foundations rather than replacing prior work.
- The approach created clear phases with defined endpoints, guiding teams toward increased capability and improved behaviors.
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Facing Similar Operational Excellence Challenges?
- Managing multiple sites with inconsistent operational and maintenance practices.
- Seeking to reduce unplanned stops and enhance production reliability.
- Looking to embed operational excellence as a strategic driver across the organization.
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