$10B+
Annual revenue
Chemical Manufacturer Harmonizes Processes and Standard Work: Driving Productivity and Knowledge Retention Across Global Operations
Industry: Chemicals
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: People and Organization
Our Client
A global specialty chemical and performance materials company operating multiple sites worldwide, with revenues exceeding $10 billion.
The Challenge
The company faced fragmented processes and inconsistent standards due to site-specific practices, acquisitions, and workforce turnover.
- Global productivity gaps: Need to improve efficiency and reduce costs across sites.
- Disparate processes: Inconsistent work practices between locations.
- Lack of organizational clarity: No common model with defined accountability.
- Aging workforce: Rising attrition risked loss of critical knowledge.
- Operational complexity: Fragmentation stemming from multiple acquisitions.
Real Results Achieved Together
By implementing standardized work processes and a harmonized organizational model, EFESO helped the client achieve significant cost savings, capacity gains, and improved operational efficiency.
$25M
Cost reduction via organizational optimization and de-layering
15%
Capacity increase within the current production year
$12M
Reduction in non-conformance materials and disposal costs
Transformation Impact
- Accelerated global implementation through standardized templates
- Enterprise-wide adoption of standard work processes and organizational model.
- Clear accountability and aligned roles across all sites.
- Enhanced knowledge retention and reduced dependency on key personnel.
- Faster implementation enabled by comprehensive best practice templates.
Our Approach
EFESO partnered with the client to design and implement a global framework for harmonized operations, supported by structured change management and governance.
Organizational Design
- Streamlined, role-based structures for each site.
- De-layered management levels to clarify responsibilities.
- Defined consistent roles to improve alignment and agility.
Standard Work Implementation
- Developed and deployed standard work processes tailored to site needs.
- Created supporting materials: 60 process maps, 90 role templates, 600+ pages of work instructions.
Change Management & Capability Building
- Structured programs to ensure adoption and sustainability.
- Training and coaching sessions for employees across all levels.
Program Management Office (PMO)
- Oversaw global rollout, monitored progress, and ensured consistent execution.
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Facing Similar Operational Complexity Challenges?
- Fragmented processes and inconsistent standards across sites.
- Increase productivity and operational efficiency globally.
- Reduce costs while retaining critical knowledge.
- Looking to implement standardized work and harmonized organizational models.
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