Read more: Thelios Eyewear: WIP reduction by 35% by synchronizing the Value Chain
Read more: Lamb Weston / Meijer: Creating a sustainable continuous improvement culture leading to...
The client is a contract pharmaceutical manufacturer of Capsules for both Pharmaceutical as well as Health & Nutrition
Read more: Lean Labs Project Improved Productivity by 33% across Pharmaceutical Product Portfolio
The client is a Pharmaceutical group which has a €15 Billion turnover with approximately 15,500 full-time employees working from 100 sites and offices worldwide.
Improving competitive performance by applying a LEAN approach in an end-to-end retail value chain
Global lubrication additives & synthetic base fluids manufacturer (Business unit of a major chemical group).
A 40 BN group and 1200 plants all over the world takes control by installing a global Operational Excellence program to make even more quality products without increasing market prices.
Read more: How to make more quality products without increasing the market prices
Contract Management Excellence to improve end-to-end Project execution
Supporting progression of the 3 Companies along the dimensions of strategy, operational performance and people.
The company is the manufacturer of niche and highly seasonal products.
The client is a global leader in Materials, Solutions and Chemicals, ranked in the top 10 of the European chemical companies. EFESO performed a Proof of Value in one of the flagship plants of the company, a plant which manufactures half-finished products from raw materials.
The client was facing high maintenance costs as 43% of maintenance jobs were unplanned and urgent and therefore often had to be scheduled for night shifts or weekends.
Over a six months period, we reviewed the relevance of predictive maintenance across all equipment families in the plant. We worked intensively with maintenance, process experts, IT and their data science teams on developing a system to detect and avoid failures for 17 different equipment families and brought online a total of 33 equipment.
The main objectives were to prove the business value of predictive maintenance and to develop the client’s in-house capability to autonomously select, develop and implement predictive maintenance solutions for their assets.
EFESO support was focused on:
The client produces Urea in a large-scale Urea reactor, and it is the core ingredient to downstream chemical plants on the same site.
14 months previously, problems with the Urea reactor began and since then, the reactor has come to a standstill 4 times due to a process failure. In fact, the problems were so severe that output reduced to less than 50%. Losses amounted to more than €10 Million
The client’s efforts to resolve the problem were without success and the root cause(s) could not be identified.
EFESO was asked to guide an expert team to identify the root cause:
The Senior Technologist Urea Factory said “In my 36-year career this is the most frustrating problem I have ever had to deal with. I would never have guessed that that was the root-cause”
Our Client is one of the world leaders in specialty chemical, active in more than 100 countries around the world and with over 33,000 employees.
After a strategic “reset” of the organizational setup, the Client needed to develop and harmonize the maintenance function. There were some “jewels”/best practices available in different sites but not shared across the network. The need to strengthen the ONE TEAM mindset, to ensure one way of working, as well as to prepare expectations for long-term change was critical. They were for example willing to install autonomous transformation infrastructure to improve asset reliability and maintenance costs. As such they needed to harmonize the maintenance function and improve cross-collaboration to optimize maintenance investments.
EFESO Consulting supported the leading specialty company in two phases:
Phase 1:
Phase 2:
Quantitative results:
Qualitative results
The client manufactures luxury vehicles with an already established Lean Production System and high variant spread. However, the company was facing several challenges:
EFESO supported the automotive Client by:
Overall, a targeted implementation with prioritization of metrics.
The Client, a global Aerospace & Defense player wanted to develop a 4.0 World Class Manufacturing (WCM) system and a digital strategy for both the Group and its local sites.
They also wanted to generate additional savings on transformation costs (compared to “traditional” WCM budget), as well as to support the management, control and reduction of the Covid-19 risk.
We supported our Aerospace & Defense Client by:
The Client is a leading independent Maintenance, Repair & Overhaul (MRO) solution provider, specialized in APU, engine parts and landing Gear MRO, for civil and military aircraft. After the merger of its 3 main divisions, the Group identified the need to develop a common Operational Excellence program mainly targeting:
EFESO supported the Client by:
Business process results:
Maintenance and Repair processes results:
Achievements for cultural change facilitation:
Read more: Launching an Operational Excellence program for a MRO solution provider
The client is a global chemical company with a turnover of €8bn. This project was run at one of their production sites in the Netherlands, where high tech fibers are produced with around 750FTE. The client needed to adjust the cost structure to realize economies-of-scale for planned future expansions and the management needed data driven analyses to be able to make the necessary decisions.
This analysis involved understanding the effectiveness of workforce, asset utilization, performance control system, leadership, and culture.
We supported our global chemical client by:
OQ Chemicals is a global leader in oxo chemicals with operations in Europe, Americas and Asia. The group has already been questioning its existing approaches and decided to boost its sustainability strategy by defining and implementing a very structured and clear roadmap to reduce their GHG emissions over the coming years.
Our goal is clear: to become a climate-neutral company until mid of the century, meaning until 2050 - or even before
- says O. Borgmeier, CEO of OQ Chemicals.
EFESO supported OQ chemicals by:
This program is the result of a process started already years ago, bundling all our activities under one single roof. It represents both a very structured approach and a clear roadmap towards our goal of climate neutrality. While this long-term goal is around two decades in the future, we are already in the middle of implementing it
Balzarek adds.
Concrete measures for the next years are clearly defined and intermediate targets are in sight. With the year 2017 being the baseline, OQ Chemicals will reduce its greenhouse gas emissions by 18% until 2025, and by 30% until 2030.
(Christoph Balzarek, EVP Corporate Development at OQ Chemicals)
If you are curious on this case study, get in touch with Marcia de Troyer
Read more: "Reduce Program” - Boosting GHG reduction to become climate neutral by mid of the Century
The client is a multinational group and global leader in the cosmetics industry. Their factories already use EFESO digital Performance Control System, and have decided it is time to deploy the tool into the distribution centres. The pilot covered two warehouses from different business units.
The aim of the client is to digitalize the DC’s existing PCS because the current process with paper boards was inefficient. Information hardly circulated and the operators were not involved in the meetings. The project consists of helping the client launch a successful POC (proof of concept).
EFESO helped by:
The Client is a Pharma start up launching a genetic treatment for prostate cancer and wanted to introduce a digital Dynamic DSI (Demand – Supply – Inventory) solution to ease the preparation and execution of the Executive S&OP:
EFESO supported the client in identifying a digital solution that best matched the Client’s needs, expectations and utilization and supported the implementation of the solution taking into account and managing Processes and Human Dynamics.
The client is a Global Distributor of electronic equipment and electrical components with a high service level, multi-channel customer offer.
The client is a world leader in the development and manufacture of mainly lactose-based excipients. Production is based on make-to-stock & make-to-order principles however, even though the MTO element (highly manual specified products from a designated site) only makes up a small part of orders, it generates ~30% of profit.
Also, the IT landscape is made up of unaligned solutions which cause manual (re-)work and inefficiencies. Currently there are unfulfilled business requirements especially data transparency in in-process-control, electronic batch record and customer portal.
EFESO supported by:
A leading pharmaceutical company engaged us to increase project workload capacity at their R&D facility. The site was responsible for the development of the next generation of biological derived drugs, including a $6 billion/year blockbuster.
EFESO supported by:
Over the next 3 years, the client wants to grow revenue and EBITDA. It also wants to improve business resilience, offer efficiency and sustainability, as well as change the way of working to be more proactive instead of only reacting to competitors' actions.
Its objectives were to:
EFESO supported by:
The company is a leading player in the Automotive sector. The project relates to the launch of Connected Services to their prestige brand across 3 continents to meet customer expectations and key industry trends where ~96% of new vehicles are projected to be connected by 2030, from ~48% today. Ensuring coherent alignment to the wider group whilst allowing for the services to be exclusive was key.
The company is a leading premium player in the Automotive sector. The project relates to the procurement strategy agenda definition and management. Each category was assigned a team with the relevant technical expertise, and the same agenda was handed to everyone for consistency. The final output resulted in the delivery of a Procurement Strategy, detailed by category and coherent with overall business direction.
Read more: Progression Strategy in luxury carmaker delivers a Business focused Procurement Strategy
The client is a leading global manufacturer of luxury cars, known worldwide for the prestigiousness of its brand and for the performance and design of its vehicles.
Following their strategic plan, a new industrial plan had to be developed - including the definition of new footprint and flows for the main technological areas including bodyshop, vehicle assembly and logistics.
The management required the new footprint to be digital and state-of-the-art, using the most recent successful Industry 4.0 concepts in order to meet the desired combination of flexibility, quality, capex and opex costs.
EFESO supported by:
The client is a leading global manufacturer of luxury sports cars, known worldwide for the prestigiousness of its brand and for the performance and design of its vehicles. The client, to align its offer to the latest market trends and to satisfy customers’ needs, decided to explore the opportunity of launching Connected Services as a standard feature on its cars. These services needed to be compelling and express the exclusivity of the brand.
The Client is one of the largest technology suppliers for food processing and a wide range of other industries with over 4 bn EUR revenue worldwide and over 18,490 FTEs.
In 2018 they launched a Procurement review program with target savings of 53 mEUR over 2 years.
During the program, some problems and complexities emerged linked to there being different entities within the client, related to recent acquisitions.
Our assignment was to provide support to accelerate this programme’s performance and results, focusing on 4 redblocks identified: Subcontracted Manufacturing, Field Assembly, RFQ and Negotiation Factory.
We quickly mobilized and brought additional capability and capacity to help the company in filling and delivering the savings pipeline.
The team was split between different redblocks, and activities were carried on in parallel in different countries.
The Client is a global leader in tobacco products (both traditional and RRP – reduced risk products). For its next generation RRPs the client wants to reduce the cost of the machines purchased from leading OEMs. At the same time, the Client improve the relationship with its strategic supplier and setup a new collaboration framework, through a Design To Value working together project.
EFESO was appointed in order to setup and run the Design to Value Working Together project between Client and its OEM supplier, and EFESO’s role comprised of the following:
As a result of the project the client:
Read more: Design to Value project in the Tobacco industry attaining 30% equipment price reduction
The client is a Global Business Unit of a key player in the chemical industry. In the context of mitigated financial results, it has decided to firm up its cash management, with a major focus on inventory (working capital) The client requested our support to help them hit the inventory reduction target defined at Corporate level (short term), and improve the teams’ maturity with regards to inventory management (long term) EFESO was working in partnership with the Global Business Unit, and the in-house Excellence Center.
The project was divided into 3 phases. EFESO supported with the first two:
During the quick-win phase: the target has been achieved and inventory has been reduced by 40 Million € over a 5 months period (a reduction from 250 M€) Teams in US, Asia and Europe have been trained in Inventory definition algorithms & methodology to calculate the optimal inventory level Created alignment within the client’s Supply Chain leadership concerning Inventory Performance Management to deploy KPIs and determine where to embed them into the existing S&OP meeting structure. In parallel, several actions were conducted to reduce SMOG (creating clarity and transparency on figures, clarifying the accountabilities…)”.
The client is a global Pharma network. The company’s strategic plan aims at building a professional and competent Supply Chain Team at the core of the business, in order to achieve:
EFESO supported the client by working through three Building Blocks
Four Progression Leaps underpinned this progression to gain benefits from:
Read more: Building Supply Chain Competence and Capability in a Pharma company
The Client has 87 manufacturing sites in 38 countries, employing ±100,000 people. To respond to health needs worldwide, the client needed to strengthen production capacity, promote inter-site collaboration and increase its presence in emerging markets.
EFESO has been asked to provide support on how to develop the Maturity Assessment System to increase collaboration and efficiency in order to sustain this industrial network strategy EFESO supported by:
Read more: Maturity Assessment to accelerate speed in a pharma company
The Client produces, for the world market, inhalation products in plants in UK, France and USA. The sites’ productivity increase targets are > 10% per year. Industry 4.0 activities are seen as the main lever to achieve this target and, especially as in the production area, several Industry 4.0 elements have already been implemented. To get to the next level the client wanted to have an implementation roadmap for the complete plant network and one partner for the implementation process.
The approach we proposed followed three streams:
A global automotive supplier was facing two major challenges in its dashboard panel production: on the one hand, risks in the process chain remain undetected due to a lack of transparency and poor supplier management. On the other hand, the processing of highly sensitive materials means that even the smallest of errors in the production process can lead to the rejection of complete components. ROI-EFESO supported the customer by using a 'digital twin’ to map the entire production process step by step. This led to an IoT pilot project that pinpointed potential for improvement and triggers improvements in both production and value stream management at suppliers. As a first step, the project team defined process parameters that could affect both the performance of the plant and the quality result. The derivation of these parameters was empirically based and included initially more than a hundred different parameters, which were reduced or supplemented in the further course of the analysis. In the next step, the team verified that the existing process data had been correctly aggregated and processed and gathered data that had not been previously recorded. The team also used additional sensors to capture the new data required for the defined parameters.
The resulting database was then consolidated and analyzed in a cloud application. On this basis, the project team designed a model that reflects the process of improving the production line for dashboards as precisely as possible - in other words, all relevant parameters, their interactions and critical values. Like the process itself, this model can go far beyond the company. In the case described, for example, it can be extended to the logistics company that transports the foam, or even to the foam manufacturer. This is because the reasons behind problems in the foaming process - such as dangerous temperature fluctuations for the sensitive polyurethane - can appear at any point in the value chain. As a result, the company obtained a digital process map that tracks the entire physical process in real time and enables early intervention according to critical process parameters - a "digital process twin".
With the help of this 'digital twin’, the project team was not only able to significantly reduce the plant’s rejection rate, but also to make the correlations of relevant influencing factors on the quality result more transparent. The company also developed a prediction model of the result at the next quality gate.
Read more: Enabling predictive quality and predictive production through digital process twins
A global furniture manufacturer was offering a broad variety of different product lines ranging from luxury to discount furniture, each with its own specific sales channels. In order to reshape this kind of segmentation ROI-EFESO created a unified and integrated 'end-to-end’ process from the customer request to the delivered product that took into account all relevant stations of Value creation: from the customer experience via ordering to manufacturing and logistics.
In two workstreams ROI-EFESO took care of the back-end integration and thus everything that happens from the ERP system all the way to the production for one. For another workstream the project team accelerated the development of the digital channel, starting with the customer experience at the point of sale, working through the ordering process and on to the factory itself.
Parallel front-end and back-end teams ensured that product customization was working flawlessly from the point of sale, through production, to delivery of the product.
The solution created by ROI-EFESO is a highly innovative combination of a 3D visual space and experience and an intelligent configurator. The customer navigates between OLED screens and finds himself in a virtual, photorealistic, 3D animated room. There he is viewing his desired piece of furniture - rendered as a 3D model - from all perspectives. Furthermore, an 'intelligent' configurator is used, comparable to the car configurators used in the automotive industry. During the customer's 'try out' of his virtual product, the salesperson can configure different variants, e.g. the frame of a bed, material or backrests, and visualize them on the screens. In the future, the salesperson can use several different room settings with plant arrangements, parquet or carpet. Ambient lighting effects, i.e. different lighting scenarios for day and night, will enhance the customer experience. This mix of digital and real world turns the purchase into a "wow factor" experience.
Once the customer has preconfigured his furniture, the order can be placed at the touch of a button. The process for this is automated. Product customization via the configurator at the point of sale naturally modifies the supply chain - more variants result in smaller batches. Parallel to the developments in the front-end area, ROI-EFESO has therefore combined the ERP systems of the different brands so that the data of all production and logistics processes are now available in real time.
Read more: Realizing true end-to-end digitization for better customer journeys
In just four weeks, a pharmaceutical & life sciences company wants to plan the main focus for the Smart Factory Transformation of four plants. Workflows and key performance indicators varied by line and plant, with various digitization needs and priorities. Therefore, at beginning of the project, it was necessary to get a clear picture of the actual maturity and requirements for each location. To this end, the project team developed a scalable approach for lean transformation of the plant. After starting in individual pilot areas of assembly, it transferred the improvements to the current line and finally, with further lessons learned, to the ramp-up of the two new models. After assessing the digital maturity level of the existing production system, the project team held a joint workshop with the plant management to determine the main directions for each site. The result was a big picture that ensured a common understanding among the workshop participants as to where the journey should take them. The commitment for the joint next steps was correspondingly high.
Besides that, the participants also determined the different directions of digitization of the respective locations including topics such as data transfer, advanced analytics, digital twins or autonomous transport systems (AGVs). So-called "deep dives" were then made to explore the technological and economic details of the defined directions identifying for example areas with high potential for driverless transport systems, the size of the investment needed and the economic benefits. From this, it was possible to derive very precise statements regarding profitability / pay back of individual business cases.
At the end of the project, the project team for each location arranged approx. 40 key topics and initiatives from the previous weeks into a portfolio with three structure criteria:
Among other things, three key topics were identified, that fulfill three requirements: quickly realizable, low deployment cost and great benefits. The other focal points from the portfolio were added to the "open items" list in order to implement them later. After a portfolio evaluation of all decision-making instances in the company, the implementation of the following actions was started:
With these digitization initiatives, the company has been optimally equipped for further Smart factory transformation at all locations. Already in the planning phase, it was thus possible to improve the quality of the process and operational excellence at the sites.
The client is a start-up and sister company of a major Pharmaceutical Manufacturing and Agent firm in KSA. The client has a specific available budget to comply with, which had to be taken into account during the assessment The engagement between EFESO & the client is for penetrating new markets in the medical appliances & veterinary products field.
EFESO supported by:
The client is a mid-size pharmaceutical company which produces API. They anticipated an increasing demand for one of the most strategic APIs produced in their Italian plant.
Read more: Debottlenecking project in a Pharma company saw real benefit, EUR 2,6 m
A leading pharma company engaged us to increase project workload capacity at their R&D facility whilst improving the schedule adherence of current project workloads. Advanced bioreactor labs utilization was optimized at a site responsible for the development of the next generation of biological derived drugs, including one $6 billion/year blockbuster
Read more: Real Lean Transformation in a Biopharmaceutical R&D Facility
The Benelux affiliate of an international pharma company was looking for expertise and methodology to structurally and culturally prepare their Belgian organisation for the coming year strategy, including the expansion of their product portfolio and a target of 40% in sales increase. We supported in:
Read more: Leading Progression and Mobilising for Progression
The Operations Top Management of a leading French pharma group with 10 units in France, aimed at building a more efficient model to face growth. We supported in:
Read more: Industrial master plan optimization for a leading pharma group
A leading international pharma company, operating proficiently yet in a traditional manner (S&OP with limited multifunctional involvement, Supply Chain disconnected from rest of Value Chain) seeked for vertical and horizontal integration. EFESO partnership on Digital with FibonacciLab boosted proficiency in process re-design, data management, technology understanding and change management implementation. We supported in:
Read more: Concurrent Digitalised Value Chain in a Pharma Company
A leading company in pharma industry had the challenge to manage performance in an efficient way, reducing bureaucracy and improving its knowledge capitalization efforts. To digitalize its performance improvement meetings and problem solving process we implemented Solvace solution (an EFESO Consulting partner for OpExc Saas platform) :
Read more: Digital Transformation - Progression Management System in a Pharma Company
A global provider of integrated services to pharma and biotech had developed a competitive advantage enabling a sharp growth. Yet some growth blockers existed. We supported in Order Management process re-engineering, performance measurement and implemented systemic changes through adoption and leadership:
An international leader of polymer products for various sectors including Life Science wanted a systemic approach balancing business needs, sustainable growth and agility. We supported in:
Read more: Value Chain Perfect Execution in a Polymer Products Leader
The company has shown impressive growth in International fashion retail. A request was made to perform an operational scan at the main warehouse to find improvements in:
The client is a major food retailer. Competitive pressure was driving the need for an integrated supply chain to improve store service and supply chain synergies. Challenging issues were:
Undertook Network Design modelling with store service set as the key objective:
A national food retailer grown in recent years through acquisitions. Potential distribution network synergies not been realised. Challenging issues were:
We used our standard approach with specific emphasis on:
Designed a flexible logistics infrastructure to realise operational synergies and support the business expansion plans.
Port of Antwerp is the EU’s second-largest seaport who faces several challenges in parallel: Ensuring growth in an increasingly competitive and unstable international market, managing the growing influence of pressure groups, managing the congestion issues linked to increased traffic, organizing a transition from the linear to the circular economy, maintaining the operational excellence while evolving from a sea port to a smart port, gathering data from different stakeholders and transforming these into value added information and services.
These changes, together with the arrival of new competitors, mean that the client needs to adapt continuously if it wants to stay “one step ahead” and safeguard its existence. Based on a trend analysis, interviews with stakeholders of the port platform community and employees, the future role of the client was defined. On top of the existing roles (Operator, Landlord, Authority), it became clear that the port was expected to take on a new role of Community Builder of the platform, being a facilitator to resolve structural and systemic issues to create a win–win for different players. This new role expects the client to evolve from a monopolist government institution to a stakeholder driven enterprise, which requires a fundamental change in strategy, processes, collaboration and human dynamics. This being a company wide culture transformation, EFESO worked on enterprise program portfolio alignment, leadership engagement, focused improvement initiatives and change management; collaborating with other specialist partners and with stakeholders in the port platform community.
The approach consists of:
The Client is a leading global manufacturer of car glazing. After years of limited competition, strong market pressure from competitors indicated that our Client needed to build solid E2E operational foundations across the Value Chain.
EFESO developed a tailored approach supported by the “CDVC” model. This proprietary survey technology, ensures that all the E2E domains advance their capabilities and performance standards with aligned goals and synchronized workflow, while striking the right balance between global vs regional benefits:
The Client is a luxury car producer, which is suffering from the lack of a single reference for the Product Development Process, resulting in no standardization, synchronization, best practice application, efficiency and effectiveness during execution.
EFESO supported the client with:
ONE PDP Handbook composed of:
Our client is a worldwide leader among luxury sports car manufacturers. Acceleration of continuous improvement in performances is the goal of the company, whose imperative is to deliver top class in quality and, at the same time, be capable of attaining Excellent Operational Performance in vehicle production and assembly processes, by exploiting state of the art technologies and digital opportunities.
EFESO supported with a 360-degree assessment of both the manufacturing and supply chain processes, in order to find opportunities at different levels to leverage the Human Dynamic aspects and the new digital / Artificial Intelligence solutions.
The key deliverables have been a detailed roadmap of initiatives covering:
Our client is a Swedish leading OE supplier with manufacturing plants around the world suppling industrial parts and services globally. It had decided to move from a fragmented Demand Planning to an Integrated Demand Planning process in 50 sites and 20 warehouses. This would be the biggest change in the client’s demand chain for 30 years, dramatically impacting staff roles and responsibilities and ways of working. EFESO was asked to do a change readiness assessment of the first two deployed plants, as well as the affected warehouses with the objective to deliver a HD reinforced deployment plan for the coming planned plants.
To establish a sustainable Progression/implementation (P) of a project both the Quality (Q) of the solutions - the design of the systems, tools, structures, plans, procedures, roles etc. and the Adoption, Activation, Anchoring (A3) of the solutions - the way people are relating to the device/the solutions, need to be addressed and focused. Illustrated by the logic [P=Q x A3] formula.
HD reinforced deployment plan based on gaps identified by the assessment which led to a more effective, accelerated and sustainable implementation plan (considering both the hard and soft aspects). Some examples:
Upgrade of the global implementation plan with the best practices of the pilot sites:
The client is a Brazilian company involved in the sustainable development of cosmetics and beauty products and was founded in the early 1960s.
The client has a direct sales model with approximately 5.7 thousand collaborators, over 1 million female consultants and a portfolio of 739 product.
Read more: WCOM™ implementation in a Cosmetics company with +20% in OEE and +22.6% in OTIF
The client is a family business and a leader in the French and European cosmetics industry. The group is present in more than 100 countries and has a turnover of more than 2 billion €.
The Leaders of Group Operations wish to:
EFESO supported by:
The client is a leading consumer goods company, wanting to improve overall laboratory performance in the areas of quality, productivity and analyst engagement.
The targets were specific to individual sites and were dependent on complexity and level of lean maturity.
A further aim of the program was to improve communication with and visibility around global functions of operational performance.
EFESO supported by:
Our client is one of the biggest French Groups in the cosmetics industry, with around ten production units in France. In a challenging economic context (strong competition, productivity concerns and consumer fear towards industrial products…), the Operations Top Management aims to design a new Industrial Master Plan (IMP) to cover the period up to 2030:
In the short term it wishes to optimize the current IMP i.e. reduction of complexity, optimization of flows and processes.
In the long run it needs to build a more efficient model to sustain growth at a competitive cost.
EFESO supported by:
Our Client is a top player in the Aerospace Industry. Securing the ramp up rate of specific aircraft sections and reducing Recurring cost (RC) target were the company’s main challenges. The shopfloor stayed in firefighting mode, basic routines were not installed and the interfaces with key support functions were not well defined.
In this context, consultants now employed by EFESO supported the client in a 22-week project by:
One of the leading actors in the Aerospace Industry, partner of the major airlines and technological leader for carbon components, with a turnover of 2.7 billion €. The client needed to reduce costs, accelerate deliveries and renew its approach to industrial engineering. EFESO supported by:
Read more: A lean project in Aerospace & Defence with a lead time reduction of 50%
An international leader in the Beer sector present in 70 countries with more than 150 breweries spread across the globe. The company decided to launch a global Continuous Improvement initiative to generate cost efficiency improvements to support new acquisitions while at the same time creating a common 'way of working’ throughout its Supply Chain Operations.
EFESO supported in:
A global player in the food industry faced challenges: profitable growth acceleration and fixed costs continuously increasing in value and in percentage versus gross margin but with an EBITDA lower than that of the main competitors.
EFESO worked in tandem with the executive team to redesign the organization in 100 days through four complementary approaches:
Read more: Strengthening a fit to win organization in the food industry
The company is a retailer that is gradually increasing its online sales and divesting its food business. Sales are decreasing slowly and profits are under pressure. The DC struggles to:
We ran a diagnostic to identify the potential and mobilised a 3-year program that led to:
Global manufacturer of helicopters wanted to profitably increase market shares in both mature market segments and innovative niches. Investment in key Design to Value initiatives on two main product platforms, one dating back 20 years and one game changer in the industry. We supported in:
Results
Read more: Design to Value & Should Cost practices to sustain advanced Procurement strategies
An Italian leader in high-speed trains design and manufacture of, with more than 2,000 employees, entered into separate contracts for the design and manufacturing of 100 high-speed diesel trains. This was in response to the need of a primary railway operator to modernise its train fleet.
EFESO was asked to carry out industrial and economic evaluations and to work in a joint task force alongside the legal office and the company’s management to:
Results
One of the leading worldwide helicopters manufacturer, with 5,000 employees, which was not able to respect promised delivery times and avoid high extra-costs due to the request of shorter delivery time, an increase in complexity of configuration and the high costs of late configuration. In this scenario, EFESO was asked to:
A professional Italian football club was wanting to achieve important savings in different areas (marketing, catering & food, facility mgt, materials & prof service, utilities & municipality, rental, travel and digital strategy). In tandem with the client, EFESO launched an Indirect Spend Optimisation programme, composed of three steps:
Read more: Indirect spend optimisation programme in a soccer club
A French company specialized in the breeding, processing and marketing of poultry as well as in the preparation of meals.
EFESO was engaged to support the Executive Committee progress towards sustainable and profitable growth through their 5 years strategy plan for national branded products.
The deliverables of the project included:
An ingredients supplier facing a highly aggressive and competitive manufacturing market. The company had to develop new grades, reduce harmful byproducts and optimize cost-effectiveness. EFESO supported the senior management with:
A world leading malt producer set the objective to double growth, mainly in Asia, Pacific and Africa, and EBITDA within 10 years. To achieve this, the company needed to define an operations strategy to support business objectives with limited CAPEX.
Starting with a pilot region covering continental Europe and export activities to Africa, Asia and Southern America, EFESO supported in:
An accelerated process managed in 100 days delivered:
A leading confectionery manufacturer reviewed their Operating Supply Network (OSN), a global network of 22 factories, 68 in-house warehouses and 240 third-party DC’s serving over 100 markets in 3 regions.
There were no consistent standards across Customer Services, Planning, Warehouse and Transportation. People worked in different ways, SAP was applied variably with no consistent operating model. Skills and capabilities needed progression.
EFESO provided project management and designed a new industrial roadmap including:
After the first stage of the project:
This is now being rolled out across the business as part of the Progression Plan.
A leading manufacturer of fresh dairy products faced a low operational profit level (2% versus N° 1:14%) despite turnover growth and a loss of market share of the third player in the market. This was mainly due to the impact of a growing complexity: internationalization, market volatility, fragmenting consumer demand, multi-sourcing.
A global performance program was needed to eradicate value-destroying complexity that does not add any competitive advantage and differentiation and to manage value-creating / adding complexity reducing negative impact on direct and indirect costs.
EFESO deployed a complexity optimization process:
The client is a wholesale/cash & carry division of a global multiple format retailer carrying food and non-food product ranges for trade customers. We supported the client in:
Results
The company is a national food retailer that has grown in recent years through acquisitions. As a result, the potential distribution network synergies had not been realised. Challenging issues where:
We modelled the future demand per postal code and the effect on the supply chain. We ran scenarios to find the best option for our client:
The company is a global beverage firm with production sites in over 60 countries. A continuous improvement program (already established in manufacturing) needed to be extended to logistics, supply chain and planning
Results
Our client is going through a process of establishing an omni-channel strategy. This requires a restructuring and integration of its distribution network. The opportunity for change at it’s key distribution center includes:
Results
A leading global company, active in the development and manufacturing of tires for automobiles, trucks, and motorcycles. Due to growing competition from emerging countries and from incumbent leaders, quality and differentiation have become critical success factors. In order to maintain competitiveness and operational excellence, a program was launched to address complexity costs and improve the capability to master complexity more efficiently by:
Results
Read more: Complexity reduction in a tyre manufacturer achieving +30% on Ebitda
A world leader in Aerospace & Defence was willing to establish a joint venture with a foreign partner to develop, produce and market a new product. EFESO was asked to help quantifying the background IPR value in order to build the Joint Venture scheme and prepare the documentation to support the negotiation with:
Results
An Italian leading company which designs, builds, integrates and supports complex systems for commercial and defense markets worldwide, was playing a key role in world-class aircraft programs. This company was fully engaged in an advanced world-class program for a twin-jet airliner led by a global OEM. To maintain good business relations, it indirectly admitted its fault and signed a contractual amendment entitling the OEM to claim for damages. EFESO was appointed as technical expert to perform:
A leading electrical company whose central Contract Management unit had recently developed a staged roadmap for achieving Contract Management Excellence and need external expert support. EFESO was engaged to:
The client was a leading global tobacco manufacturer based in Turkey and losing in GBP10m p.a. due to a lack of critical mass which was driving a high cost to serve. The issues to overcome were:
EFESO supported by:
Read more: Route to Market for tobacco manufacturer results in huge savings from greatly improved...
The client is a diverse conglomerate in an emerging economy with interests in manufacturing, processing and distribution including food, beverages, dairy and agriculture in Sub-Saharan Africa with a turnover of $1bn. The group operations cover 90% of the region, including 28 major cities served by various multi-temperature transport modes (including road, rail and barge).
With a growth trajectory of c.300% over three years, the business needed to implement a fit for purpose Supply Chain across the group. The objective of the program was to develop group supply chain capabilities (infrastructure, organization, people, process, systems) through a blend of step-change and continuous improvement. This progression was supported by a learning and organization development approach to deliver sustainable competencies, capabilities and skills.
EFESO supported by:
A progressive three-phase roadmap was supported around 3 themes:
Further support was provided by EFESO in the client’s journey from a highly decentralised and function based organisation to a cross functional driven structure, able to leverage strengths from both an end to end supply chain and business unit synergies perspective.
The client was a worldwide custom-made fashion and home furnishing company offering home delivery. It operated in a promotion-driven market. Although successful there was:
Therefore, the challenge was to improve customer satisfaction, dramatically improve service levels, reduce costs of quality and optimise pricing and promotions.
EFESO supported by:
Read more: Business Aligned Network Design in Textile company results in +20% sales and margins
The client was the Finnish & Russian Packed Lubricants division of the world's largest publicly traded integrated petroleum and natural gas company, whose logistics & distribution operations were outsourced.
The client needed to identify the best logistics & distribution model and evaluate potential service providers.
The issues the client faced were:
EFESO Supported by:
Our client is a Nutrition laboratory in a Global multi-site environment in Europe, USA and Asia. The objective of this program was to improve laboratory efficiency and effectiveness through the utilization of lean tools and principles. It covered a range of GMP laboratory types including analytical chemistry, microbiology, environmental monitoring, incoming materials and in process control. We supported in:
Read more: Improve Nutrition laboratory efficiency and effectiveness
Our client is an Active Pharmaceutical Ingredient (API) company located in Ireland. The objective of this program was to reduce the overall lead time from the manufacture of the product to the final release (Quality Control and Quality Assurance). We supported in:
Read more: Reduce the overall lead time for an Active Pharmaceutical Ingredient
Our client is a Contract Research Organization (CRO) in the USA. Our client, a leader in the third-party contract testing field engaged us to improve the throughput time from sample receipt to COA approval. This environment is quite a challenging one given the paucity of forecast data and the need for a dynamic, flexible workforce to meet challenging customer turnaround times. Additional foci of the project included the creation of standardized roles and a robust and consistent capacity planning process. We supported in:
Read more: Throughput time improvement in a Contract Research Organisation
Our client is a Solid Dose (Small Molecule) Pharmaceutical company in a Global multi-site environment in North America. The primary objective of this project was to reduce batch record review and disposition times to facilitate accelerated release of product to market. Ancillary objectives included increasing QA team productivity through implementation of capacity planning and standard work and streamlining of deviation management processes. We supported in:
Read more: Reduce batch record review for a Solid Dose (Small Molecule) Pharmaceutical company
Our client is Biologics Drug Substance and Drug Product manufactorer in a Global multi-site environment in Europe, USA and Asia. This project was targeted to improve the speed, quality and productivity of the QC functions at individual sites to contribute to a more stable supply of product. Additionally, it focussed on development of a standard capacity planning tool and process to provide visibility of resources at the site and network level. We supported in:
Read more: Lean Lab approach in Pharma company gains 15% productivity improvement
An international food, snack & beverage company with a large global footprint of manufacturing and distribution sites needed help setting up and deploying a sustainable lean culture, initially, in multiple European sites. In tandem with EFESO, the client introduced Human Dynamics elements into the existing programme from top floor to shop floor in the following manner:
The client is a global producer of natural gas-based fertilizers and industrial chemicals, employing around 3000 people. Confronted with an ageing workforce at the sites, increasing environmental regulations, internal pressure to reduce safety risks and need to improve the plant performance a Behavior Excellence initiative was launched in 1 key site in the Netherlands as a blueprint.
Our client is a high-end paper and board producer only utilising virgin fibres. The reliable supply of wood, preferably FSC-certified, is critical for our client. Our client has three main sources of wood, namely: its own forests, international import and wood from private landowners. The latter is secured via an organisation purchasing harvesting rights from private landowners. The set goals were to increase the amount of FSC-certified wood, stabilise price levels and increase volume per purchaser. The tools used included a mixture of Lean Administration, Performance Behaviour and Sales Growth.
Our client is a large paper manufacturer facing an investment in a new paper machine, increasing their capacity tremendously. By integrating Project Management, Early Equipment Management and WCOM-methodology the investment project reached exceptional results and went beyond the purchase of the new machine and involved the restructuration of the entire mill.
Our client is a sawmill producing 85 000 sqm of customized sawn timber for carpentry. The sawmill was at risk of being closed due to a declining trend in efficiency in the production process deriving from a high amount of breakdowns, shortstops and quality problems. To stay in business our client needed to increase efficiency from 30 % to 34 %. After conducting an analysis to identify the biggest losses, cross-functional improvement teams were put together to eliminate losses and improve efficiency. In addition to this, all employees were trained in improvement methods.
Our client, the Food Specialties branch of a major chemical group, aimed at increasing the output of its enzyme business, which was constrained by the supply. Confronted with a lack of performance culture and of execution discipline, the management had the ambition to have full transparency, to provide an integrated view on performance and to leverage on digital and advanced analytics, with the objective to increase the output of a site in France by 40% in 12 months, without major capacity investments.
An ambitious Digital Performance Control System was implemented during 6 weeks through a step-by-step and bottom-up approach: starting with daily site, then underlying sectors, adding problem solving, leveraging on behaviour (prepare, facilitate, action closing, …), improving meeting content in a participative way, integrating data.
The client is a multinational consumer healthcare / pharma company, with EUR 33 billion in sales, is present in 100 countries and employs more than 110.000 people.
The ambition was to become n°5 and n°2 worldwide in two product categories, creating and maintaining an entrepreneurial attitude for smart decisions taken at global level.
Market, business, trends & needs analysis was performed through a network of experts and innovators to capture growth opportunities.
The assignment contained development of distinct growth strategies considering the «company fit» including capabilities, culture, brand analysis, M&A opportunity identification and innovation stream.
Multiple risk analyses and business cases for deployment of global and regional growth initiatives were developed.
Read more: Developing creative growth strategies to capture value
Our client is going through a process of establishing an omni-channel strategy. This requires a restructuring and integration of its distribution network. The opportunity for change at it’s key distribution center includes:
The client is a world-leading global packaging manufacturer headquartered in the Nordics but present in 30 countries and 80 sites around the world with18.000 employees and net sales of EUR 3.4 billion.
The client needs to significantly reduce waste, productivity losses and conversion costs, so they approached EFESO as we have done extensive work and TPM based operations achieving excellent results worldwide with a similar operational entity and structure.
To achieve the desired goals:
The client is a leading postal operator and universal service provider, offering an array of mail, financial and insurance products through its dense points of sale network. As the Service Levels to clients became ever more important, the client wanted to know the status of the level of engagement amongst employees and to understand which points of attention needed to be managed to maintain and increase service. With the boundary condition to prevent creation of “another survey” adding to the already numerous surveys the population is faced with on a yearly basis, EFESO was asked to build and deploy a monitoring system to understand the engagement and to help define and implement possible remedial activities.
Read more: Establishing continuous Engagement Monitoring in a leading postal operator