Discover how EFESO works side by side with clients across industries to achieve measurable, lasting impact. Each story captures the challenges our clients faced, the actions we took together – from boardroom to shop floor – and the tangible operational and financial results delivered.
$6.5M
Annual margin gain through increased crude throughput
Oil & Gas, Sustainable Energy
Manufacturing
Operations Strategy and Transformation
Eliminated naphtha bottleneck through lean optimization, accelerating crude throughput 25% and capturing $6.5M margin gain.
$2.5M
Value Unlocked
Oil & Gas, Sustainable Energy
Operational Excellence
Transactions and Turnaround
A U.S. refinery reduced tank maintenance downtime and unlocked $2.5M in value by simplifying processes, improving coordination, and applying Kaizen-driven transformation.
$16M
EBITDA uplift opportunities identified
Industrial Manufacturing
Oil & Gas, Sustainable Energy
Private Equity
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Transformed manufacturing operations for energy technology leader, doubling production output while identifying $16M EBITDA opportunities.
+$10M
Annual margin improvement through better loss control and operational routines
Oil & Gas, Sustainable Energy
Manufacturing
Operational Excellence
A major refinery embed lean practices, improve operational performance, and strengthen cultural engagement, generating significant financial and organizational impact.
$62M
Increase in annual EBITDA
Oil & Gas, Sustainable Energy
Industrial Strategy, Operating Model & Transformation
Operational Excellence
Operations Strategy and Transformation
A large U.S. refinery improved from 4th to 1st quartile performance, delivering $62M in EBITDA through Lean transformation, improved maintenance execution, and enhanced workforce productivity.
84%
master data made usable within 6 weeks
Oil & Gas, Sustainable Energy
Manufacturing
Operational Excellence
A polyethylene manufacturer improved cash flow and reduced costs by transforming spare parts inventory management, enhancing ERP data quality, and implementing structured sourcing strategies, enabling faster data usability and sustainable operational control.
$290M+
Annualized Benefits
Oil & Gas, Sustainable Energy
Logistics and Distribution
Operational Excellence
Operations Strategy and Transformation
Supply Chain
A downstream refining company improved performance across six sites, delivering over $330M in EBITA through coordinated improvements in maintenance, contractor management, capital deployment, and operational standardization.
25%
Reduction in COGS across 10 major product families
Industrial Manufacturing
Oil & Gas, Sustainable Energy
Cost and Value Engineering
Manufacturing
R&d and Product Profitability
Restructured product development and optimized designs, achieving 25% COGS reduction across ten product families.
98%
Preventive maintenance compliance
Oil & Gas, Sustainable Energy
Manufacturing
Operations Strategy and Transformation
People and Organization
Overcame siloed teams and change resistance through integrated maintenance structure, delivering $10M savings and 98% compliance.
40%
Reduction in overall tank workflow time
Oil & Gas, Sustainable Energy
Cost and Value Engineering
Manufacturing
Procurement
Streamlined tank management workflows at 200 Mbpd refinery, achieving 100% schedule compliance and $8M annual savings.
15%
Increased winter capacity
Oil & Gas, Sustainable Energy
Manufacturing
Operations Strategy and Transformation
Supply Chain
Eliminated seasonal pipeline reversals through terminal modifications and routing optimization, increasing winter capacity 15% and annual income $2M.
$1.4M
Annual margin impact through additional asphalt shipments
Oil & Gas, Sustainable Energy
Lean Lab
Manufacturing
Operations Strategy and Transformation
People and Organization
Lean rail operations eliminated congestion and FRA violations, unlocking $1.4M margin and 30% inventory reduction.
$40M
Increase in rail loading capacity delivering direct annual impact
Oil & Gas, Sustainable Energy
Transportation, Logistics and Services
Digital & Ai
Manufacturing
Operations Strategy and Transformation
Supply Chain
Deployed Lean methodology across rail operations, eliminating congestion and unlocking $65M in capacity and cost savings.
$10M
Business value generated from hauler uptime improvements
Oil & Gas, Sustainable Energy
Cost and Value Engineering
Lean Lab
Manufacturing
Operations Strategy and Transformation
Coached CI practitioners using Kaizen methodology to eliminate capacity constraints, achieving $150 million in savings.
15%
Increase in daily railcar throughput at two sites, generating $10 million in additional annual margin
Oil & Gas, Sustainable Energy
Digital & Ai
Lean Lab
Operations Strategy and Transformation
Supply Chain
Optimized rail logistics at four petrochemical plants, achieving 15% throughput increase and $10M additional margin.
40%
Reduction in craft workforce with increased productivity
Oil & Gas, Sustainable Energy
Cost and Value Engineering
Lean Lab
Manufacturing
Operations Strategy and Transformation
People and Organization
Applied Lean methodologies to petrochemical maintenance operations, reducing craftsmen by 40% while boosting productivity 360%.
Chemicals
Oil & Gas, Sustainable Energy
Operations Strategy and Transformation
People and Organization
Sustainability
Transformed fragmented SHES programs into world-class framework, integrating sustainability and driving operational excellence across global sites.
$195M
In annual EBITDA improvement
Oil & Gas, Sustainable Energy
Cost and Value Engineering
Operations Strategy and Transformation
R&d and Product Profitability
Transformed energy sector product development through Lean NPD, delivering $195M EBITDA improvement and 93% SKU reduction.
12%
Reduction in overall system costs
Industrial Manufacturing
Oil & Gas, Sustainable Energy
Cost and Value Engineering
Manufacturing
Operations Strategy and Transformation
People and Organization
Industrial cooling systems provider faced operational complexity post-acquisition. We integrated operations, standardized processes, and optimized production planning, improving delivery performance by 45%.
$23M
In annualized savings realized
Oil & Gas, Sustainable Energy
Cost and Value Engineering
R&d and Product Profitability
Supply Chain
Oil equipment manufacturer shifted from engineer-to-order to configure-to-order strategy, achieving $23M in annual savings.
Discover measurable outcomes achieved with our clients
See how transformation happens, from boardroom to shop floor
Let’s discuss how we can deliver similar impact for you
