+200
Cost-reduction proposals developed across three product families
Idea-to-Value Approach Strengthens Competitiveness: Global Value Engineering Program Drives 3x Higher Savings Than Target
Industry: Industrial Manufacturing
Service: Cost and Value Engineering
Service: R&d and Product Profitability
Our Client
A global supplier of engineered cooling systems serving the power generation industry, with engineering teams across Europe, the U.S., and Asia.
The Challenge
The company was losing global market share as prices remained 10–20% higher than competitors’. Although customers had historically paid a premium for high-performance, customized systems, increasing competition and cost sensitivity made this unsustainable.
- High product costs eroding competitiveness and market share
- Fragmented operations with limited knowledge sharing between engineering centers
- Lack of standardization across product groups and regions
- Absence of unified engineering practices to drive cross-regional efficiency
Real Results Achieved Together
The Value Engineering initiative delivered significant savings, strengthened collaboration across global teams, and established a unified framework for continuous cost optimization.
30%
Product cost reduction depending on product and region
$30M
In total savings, exceeding the original $11M target by threefold
Transformation Impact
- Standardized design elements and components across global product lines
- Strengthened global engineering collaboration and knowledge transfer
- Sustainable cost management framework embedded across sites
Our Approach
EFESO worked closely with the client’s engineering and operations teams worldwide to deploy a structured Value Engineering program focused on cross-functional collaboration and measurable cost reduction.
Value Engineering and Product Standardization
- Conducted 11 Value Engineering workshops across three continents and six offices over ten months.
- Engaged cross-functional teams to challenge every aspect of product design and manufacturing.
- Identified shared components and processes to enable standardized designs across product lines.
Global Knowledge Sharing and Engineering Alignment
- Established mechanisms for systematic design reviews and coordination across global offices.
- Developed an implementation infrastructure to track cost savings and manage ongoing improvements.
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.
R&D and Product Profitability
Markets demand profitable innovation faster than ever. We optimize the entire product lifecycle through design-to-cost, rapid prototyping, and portfolio profitability management.
Facing Similar Cost and Standardization Challenges?
- Maintain price competitiveness amid rising market pressure.
- Managing globally distributed engineering teams with fragmented practices.
- Looking to embed Value Engineering to drive sustained cost reduction and collaboration.
Discover More Clients Results
20%
Downtime reduction
Industrial Manufacturing
Improving OEE and Production Oversight Through Digital Transformation
A die-cast metal manufacturer improved equipment effectiveness, reduced downtime, and increased operational visibility through predictive maintenance, IoT integration, and real-time production monitoring.
15%
Operating cost reduction
Resources Mining and Processing
Reducing Mining Operating Costs Through Operational Excellence
A mining company reduced operating costs by 15% by improving pit-to-plant coordination, maintenance effectiveness, supply chain performance, and operational accountability through a high-performance operating system.
25%
Reduction in project delays
Industrial Manufacturing
Resources Mining and Processing
Building a Digitally Enabled CAPEX PMO for Better Project Performance
A major mining company implemented a centralized CAPEX PMO with digital reporting tools to improve governance, cost control, project visibility, and execution consistency across its capital project portfolio.
60%
Reduction in start-up time
Food & Beverage
Vertical Start-Up Reduces CAPEX Project Time by 60%
Accelerated CAPEX execution through Vertical Start-Up methodology, reducing project timelines by 60% across European operations.
$750K
Validated savings achieved
Life Sciences
Packaging
Turning Cost Pressures Into Sustainable Profitability
Packaging manufacturer achieved $750K savings through optimized labor ratios, reduced scrap, and material efficiency improvements.
$2.5M+
Procurement savings secured
Industrial Manufacturing
Private Equity
Transforming Operational Excellence for a Private Equity Exit
Scientific instruments manufacturer faced production bottlenecks and quality challenges. We redesigned manufacturing flow, implemented lean principles, and enhanced testing protocols, improving on-time delivery to 95%.
35%
Downside risk to 10-year profit projections
Automotive and Commercial Vehicles
Private Equity
Technical and Operational Due Diligence Identifies 35% Downside Risk and 15% EBITDA Upside
Investment fund required battery manufacturing joint venture assessment. We conducted technical due diligence, operational analysis, and risk evaluation, identifying 35% downside risk and 15% EBITDA upside.
30%
Inventory cost reduction
Transportation, Logistics and Services
Supply Chain Transformation Boosted by Adoption and Digitalization: Turning Fragmented Operations into Unified Excellence
Cruise operator required operational excellence across fleet operations. We optimized crew efficiency, enhanced maintenance planning, and improved supply chain logistics, reducing operating costs by 12%.