Client situation & approach
The client is one of the world’s leading cosmetics manufacturing groups, which has 4 divisions: FMCG, Luxury, Professional Products and Cosmetic Active Products.
Our client wants to overcome a range of issues:
- Marketing comes first and Manufacturing second
- It had a bad experience with other consultants in some plants in the past
- It is not familiar with WCOM™ (World Class Operations Management) and thinks it is the best at everything
- It has never worked with a worldwide consulting company
EFESO started the implementation of a WCOM™ programme for 29 plants in 15 countries over 4 years, and it was also implemented in all new plants.
- The first plant was in Mexico
- The next 3 years covered 14 European plants
- Simultaneously working in 8 plants in North and Latin American, 4 plants in Asia and 2 plants in Africa
Results
- A successful first-time worldwide project
- 20% improvement in worldwide involvement over 2 years
- 259 teams launched since the beginning of the program
- Efficiency Improvement led to add 20% of production capacity worldwide with the same plants. OEE% from 58% to 70%
- Material losses reduction by 30% (from EUR 140M to EUR 90M)
- The group as global entity won the “Operational Excellence Prize” and one of the plants was rewarded as “Best French plant of the Year”
