$47M
Annual pre-tax earnings improvements
Driving Operational Excellence in a Multi-Site Chemical Operation: Boosting Productivity, Reliability, and Asset Performance in a Multi-Site Chemical Operation
Industry: Chemicals
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: People and Organization
Our Client
A multi-site chemical company seeking to enhance operational capacity, improve productivity, and optimize EBITDA through standardized processes and workforce engagement.
The Challenge
- Capacity and productivity pressure: Required to increase output efficiently.
- Operational reliability gaps: Recurring equipment failures affected production.
- Workforce engagement challenges: Employees needed structured guidance to sustain improvements.
- Lack of standardized operational practices: Inconsistent processes across multiple sites hindered performance.
Real Results Achieved Together
The operational excellence program delivered significant improvements in productivity, asset utilization, and reliability while establishing a sustainable performance-driven culture.
79% to 94%
Increase in overall asset utilization
17%
Productivity improvement
Transformation Impact
Integrated best practices to enhance operational reliability and efficiency.
- 42% to 77% increase in Preventive Maintenance Work Orders
- 40% to 6% reduction in Priority 1 equipment failures
- 21% yield improvement
- Improved preventive maintenance execution and first-time fix rates.
- Engaged workforce through training, coaching, and empowerment.
- Established KPIs, visual management, and operational cadence for accountability.
- Reduced production losses and optimized asset performance.
Our Approach
EFESO partnered with operations and maintenance teams to apply its Best Run Chemical Operations Playbook, benchmark performance, and implement a tailored operational excellence roadmap.
- Operating Models & Process Optimization
Streamlined processes, improved systems, and fostered a culture of continuous improvement.
- Operational Excellence Framework
Prioritized initiatives with measurable impact and guided execution.
- Workforce Engagement
Equipped leaders and employees with training, coaching, and empowerment to sustain improvements.
- Major Initiatives Implemented
Performance Management System: KPIs, visual management tools, operational cadence.
Reliability Effectiveness Program: Reduced recurring equipment failures with preventive maintenance.
Maintenance Productivity Program: Improved planning, scheduling, and work order quality.
Asset Utilization Enhancement: Minimized production losses.
Operational Discipline & Operator Care Model: Defined roles, empowered operators to address defects.
- Continuous Improvement Program: Engaged all employees in structured performance improvement initiatives.
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Facing Similar Operational Challenges?
- Pressure to improve capacity and productivity without additional capital investment.
- Recurring equipment failures and low reliability.
- Need to engage workforce in sustaining operational improvements.
- Desire to standardize processes and embed continuous improvement across multiple sites.
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