+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.
Food & Beverage
Digital & Ai
Manufacturing
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.
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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
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