9%
Points increase in OEE
BOOST and BUILD Capabilities in Packaged Foods Manufacturing: Driving Efficiency and Sustainable Performance Across Private Label Production Sites
Industry: Food & Beverage
Industry: Packaging
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: People and Organization
Our Client
A U.S.-based producer of private label snacks, beverages, and meal kits, operating multiple manufacturing sites with multi-billion-dollar annual revenue.
The Challenge
The client faced rising customer demand and operational inefficiencies across multiple sites:
- Urgent need to release capacity for key product lines.
- Low Overall Equipment Efficiency (OEE) driven by aging equipment.
- Underperforming new lines failing to meet expected output.
- High staff turnover and leadership capability gaps.
- Limited problem-solving routines restricting continuous improvement.
Real Results Achieved Together
Through the BOOST & BUILD framework, EFESO helped the client stabilize operations, increase throughput, and strengthen team capabilities. The initiative delivered measurable productivity gains and built the foundations for long-term performance sustainability across priority manufacturing sites.
17%
Increase in throughput
Transformation Impact
- Unlocked capacity to meet growing customer demand across multiple product categories.
- Established standardized operating practices and process controls.
- Strengthened leadership skills and team problem-solving capabilities.
- Embedded daily performance management routines to sustain improvements.
- Cultivated a continuous improvement culture to ensure long-term operational excellence.
Our Approach
EFESO deployed its BOOST & BUILD transformation framework, combining rapid operational recovery with sustainable capability development.
Comprehensive Diagnostic and Co-Creation
- Conducted a detailed site assessment, including OEE loss analysis, material flow, and supply chain review.
- Performed a maturity assessment on Operational Excellence systems, organization, and behaviors.
- Co-created a tailored implementation roadmap with site leadership teams.
BOOST Phase – Rapid Performance Improvement
- Focused on quick wins to stabilize key production lines and increase efficiency.
- Installed process controls and standardized operating practices.
- Resolved major bottlenecks and reliability issues to improve immediate throughput.
BUILD Phase – Developing Capabilities for Sustainability
- Enhanced leadership and problem-solving capabilities across all organizational levels.
- Established daily accountability and loss elimination routines.
- Developed a structured OpEx culture enabling sustainable, scalable performance improvements.
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Facing Similar Challenges?
- Release production capacity to meet growing demand.
- Improve equipment efficiency and throughput.
- Strengthen leadership and build a sustainable OpEx culture.
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