350K
Tons annual plant capacity
WCOM™ Boosts OEE 8.3% in 3 Months in Forestry & Paper
A kraftliner paper mill wanted to significantly increase production output and raise its operational performance. Together with EFESO, the mill implemented a World Class Operations Management (WCOM™) program. In just three months, the plant surpassed its OEE targets and laid the foundation for sustained, multi-year performance improvements.
Packaging
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Our Client
A kraftliner paper manufacturer operating several mills with a production capacity of 350,000 tons per site. The company produces high-performance kraftliner paper serving global packaging and corrugated solutions markets. Its operations require robust asset management and continuous performance improvements to meet rising output expectations.
The Challenge
The plant set an ambitious objective: rapidly increase production output from 350,000 to 400,000 tons, equal to a +6 percentage-point OEE improvement, within one year. This required both immediate wins and a scalable model for sustainable performance. Additional challenges included:
- Aggressive timing: The target demanded fast identification and eradication of performance losses
- Fragmented execution rhythms: Lack of common routines and governance slowed problem resolution
- Siloed functions: Historical separation between departments limited collaboration and transparency
- Need for cultural shift: Long-term objectives required new behaviors, not just technical solutions
Real Results Achieved Together
The World Class Operations Management (WCOM™) program journey not only delivered fast, measurable OEE improvements but also created a platform for long-term operational excellence driven by sustained behaviors and integrated routines.
+8.3%
OEE increase in 3 months
+4.0 p.p.
Long-term OEE improvement sustained over 3 years
SEK 80M
Annual run-rate cost savings achieved
Transformation Impact
- Exceeded the short-term OEE improvement target and fully eliminated identified breakdown root causes
- Increased collaboration between functions that historically worked independently
- Built a culture of shared responsibility through operational steering and pillar-driven loss eradication
- Delivered a long-term operational performance model that extends beyond technical improvements
Our Approach
EFESO initiated a comprehensive diagnostic to identify loss areas and establish a clear performance roadmap. Cross-functional teams were created and trained to drive improvement using WCOM™ pillars, including Autonomous Maintenance, Planned Maintenance, Focused Improvement, and Training & Education.
The methodology included:
- Target breakdown and deployment of robust daily operational steering
- Development of routines that reinforced clear behaviors and accountability
- Loss-driven improvement projects led by empowered multidisciplinary teams
- Continuous capability building to ensure ownership and sustainment
- Alignment of every performance action with OEE impact and strategic objectives
This structured, pillar-based approach enabled the plant to not only eliminate immediate losses but establish the governance, skills, and practices necessary to sustain performance over multiple years.
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 Unlock Hidden Capacity in Your Operations?
- Transform production losses into measurable gains without major capital investment
- Stop accepting breakdowns and inefficiencies as "just part of the process"
- Join manufacturers who've exceeded their production targets through systematic improvement
Discover More Clients Results
>98.5%
Delivery readiness level consistently maintained despite inflation, sustainability investments and 12% volume growth
Food & Beverage
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
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
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
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
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
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
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.