+120
Factories worldwide
Transitioning To Opex 4.0: A Significant Evolution
A global snacks and confectionery company had reached a performance plateau. Together with EFESO, the organization launched a step-change transformation toward OpEx 4.0, combining digital visibility and human dynamics to unlock further efficiency gains and accelerate value creation.
Industry: Food & Beverage
Service: Digital & Ai
Service: Manufacturing
Service: Operations Strategy and Transformation
Our Client
A global snacks and confectionery business with more than 120 manufacturing facilities and $30 billion in annual revenue, serving consumers worldwide through recognized brands and large-scale operations.
$30B
Annual turnover
The Challenge
After years of continuous Operational Excellence efforts, the company had driven out the most accessible inefficiencies. However, further improvement stalled due to:
• Poor data quality and granularity: Opportunities existed, but could not be captured manually at scale
• Underperforming digital investments: Some sites deployed digital tools without measurable ROI or KPI improvement
• A digital paradox: Employees were more digitally capable at home than at work, limiting engagement and productivity
• Need for visibility and adoption: Enhancing data alone was not enough without a structured program to ensure behavioral change
The business required a new way to connect data, daily execution, and OpEx methodology—evolving from traditional continuous improvement to OpEx 4.0.
Real Results Achieved Together
The transition to OpEx 4.0 unlocked measurable improvements and accelerated adoption of digital tools across the network.
+25
Percentage points Line OEE improvement at a key site within 6 months
18
Months to recover investment through cost reduction
$15M
Initial investment in shop floor data visibility and sensorization
Transformation Impact
- Strong adoption of digital tools by operators and process leaders
- Improved visibility and eradication of operational losses
- Full digitalization of the OpEx methodology underway
- Clear linkage established between data, behaviors, and business targets
Our Approach
EFESO combined its expertise in Operational Excellence, Human Dynamics, and Digital to enable both adoption and performance impact.
Core elements included:
• Aligning OpEx practices, business goals, and daily activities through enhanced data visibility
• Improving application of OpEx on the shop floor, reinforcing the connection between losses, performance systems, and behaviors
• Managing maturity differences across sites with customized support paths
• Working jointly with Solvace to deploy the Connected Worker platform, enabling digital workflows and real-time loss identification
The result is a scalable OpEx 4.0 framework that embeds digital capability, accelerates value creation, and prepares the organization for the next horizon of operational performance.
Related Services
Digital & AI
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.
Manufacturing
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Operations Strategy and Transformation
Helping organizations rethink how they create value. We strengthen performance, build resilience, and accelerate growth across every layer of your business.
Ready to Transform Your Operational Excellence Into a Digital Advantage?
- Unlock hidden productivity gains through real-time data visibility and loss eradication
- Stop watching OpEx improvements plateau while your teams struggle with outdated manual processes
- Join leading manufacturers who've achieved measurable ROI by bridging the gap between digital capability and shop floor reality
Discover More Clients Results
80%
Projects realized on-time
Transportation, Logistics and Services
Achieving Sustainable Transformation, From Vision to Strategy and Implementation, for a Major European Port
Transformed Europe's second-largest port into climate-neutral hub while increasing throughput and securing substantial EU funding.
>98.5%
Delivery readiness level consistently maintained despite inflation, sustainability investments and 12% volume growth
Food & Beverage
Unified Performance and Culture Transformation Across a Global Food Network
An eight year journey hardwired a common way of thinking and working into the organization, enabling Bell Food Group to sustain delivery performance above 98.5% despite rising costs and market complexity.
+10K
Pallet positions created through optimized DC layout expansion design
Life Sciences
Feasibility Study Enables +10,000 Pallet Pharma Distribution Center in Romania
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.
10%
CAGR in assembly labor productivity in participating plants
Automotive and Commercial Vehicles
A Competitive Award as the Catalyst for Global Factory Excellence at a global Automotive OEM
EFESO implemented a global award-based operational excellence program for a leading automotive OEM, boosting productivity, cost efficiency, employee engagement, and sustainability across the factory network.
+$10M
Annual margin improvement through better loss control and operational routines
Oil & Gas, Sustainable Energy
Co-creating the Industrial Future with Lean in a Refinery for a Leading Global Oil Company
A major refinery embed lean practices, improve operational performance, and strengthen cultural engagement, generating significant financial and organizational impact.
+5–6%
EBITDA expected in 5 years
Life Sciences
Redesigning Operations and Optimizing Supply Chain in Cosmetics Production
EFESO supported a major cosmetics supplier in redesigning operations across six factories and optimizing the supply chain, targeting improved productivity and long-term profitability.
90%
Average OTIF achieved in under two years
Life Sciences
Operational Excellence and Digital Transformation in Pharmaceutical Production
A mid-sized pharmaceutical company achieved measurable efficiency, cost, and delivery improvements at four European sites through EFESO’s Operational Excellence and Digital Transformation programs.
45K m²
Optimized factory layout (reduced from 52K m²)
Industrial Manufacturing
Restarting a Greenfield Factory Planning Process
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.