+350
Employees
Cosmetic Packaging Firm Optimizes OEE and Resources: Driving Operational Efficiency and Profitability Across Global Manufacturing Plants
Industry: Consumer Goods and Luxury
Industry: Packaging
Service: Cost and Value Engineering
Service: Manufacturing
Service: Operations Strategy and Transformation
Our Client
A global cosmetics plastic packaging manufacturer with 4 production facilities in 45 countries and 350+ employees, seeking operational efficiency and profitability improvements.
4
Manufacturing plants
45
Countries of operation
The Challenge
The client needed to increase operational efficiency and profitability at a key Dutch facility while strengthening team leadership and interdepartmental collaboration.
- Line efficiency: Improve performance across 4 packaging lines to meet production targets.
- Team leadership: Enhance team leads’ ability to manage and guide staff effectively.
- Cross-functional communication: Improve collaboration across departments involved in production.
Real Results Achieved Together
By addressing operational bottlenecks and implementing targeted improvements, EFESO helped the client optimize production performance, materials usage, and labor productivity, achieving measurable profitability gains.
21%
Potential combined EBITDA increase
4.4%
OEE improvement across 5 manufacturing lines
$235K
Assessed potential cost savings from internalized activities
Transformation Impact
- 3.5% improvement in material efficiency
- Increased line efficiency and reduced changeover losses using a SMED taskforce.
- Optimized workforce allocation and manning levels for productivity gains.
- Enhanced communication and performance tracking through shopfloor visual management.
- Internalized previously subcontracted activities, realizing cost savings.
Our Approach
EFESO partnered with the client in a two-phase approach to deliver measurable operational improvements:
Phase 1 – 4-Week Assessment
- Evaluated operations across Organization, Processes, IT/Digital tools, and Financial & Operational Benchmarking.
- Identified optimization levers and potential savings.
- Prioritized quick wins and defined a structured implementation plan.
Phase 2 – 8-Week Quick Wins Implementation
- Restored and reduced scrap in secondary processes.
- Automated painting line loading to reduce manual intervention.
- Improved OEE and optimized manning levels.
- Implemented shopfloor visual management to enhance communication and performance tracking.
Related Services
Cost and Value Engineering
Rising costs demand optimization from design through production. We apply cross-functional value engineering, zero-based redesign, and continuous cost tracking to protect margins.
Manufacturing
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Operations Strategy and Transformation
Helping organizations rethink how they create value. We strengthen performance, build resilience, and accelerate growth across every layer of your business.
Facing Similar Challenges?
- Improve line efficiency and OEE across manufacturing operations.
- Optimize material usage and reduce waste.
- Enhance labor productivity and workforce allocation.
- Wanting to implement structured performance tracking and visual management.
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