$440M
annual revenue
Global Chemical Company Boosts Performance with Lean and Predictive Analytics: Accelerating Global Lithium Operations with Structure, Visibility, and Accountability
Industry: Chemicals
Service: Cost and Value Engineering
Service: Digital & Ai
Service: Lean Lab
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: Procurement
Our Client
A global integrated lithium producer generating $440 million in annual revenue, producing battery-grade lithium hydroxide for energy storage, aerospace, pharmaceutical, and agrochemical industries.
The Challenge
The client faced high complexity in executing a multi-country CapEx program, requiring alignment across continents, vendors, and organizational functions.
- Complexity & collaboration gaps: Need for cross-functional coordination across Thailand, China, and South America.
- No structured global processes: Lack of standardized decision-making, issue resolution, and escalation.
- Limited visibility: No integrated analytics platform to track progress and performance.
- Schedule & cost risks: Poor understanding of delays and their impact.
- Vendor & interface management weaknesses: Decisions often unsupported by data.
Real Results Achieved Together
The program delivered accelerated schedules, cost savings, and improved predictability across all project stages.
8%
schedule improvement from original baseline
$27M
cost savings through procurement negotiations
70%
reduction in schedule variation
Transformation Impact
- Improved project predictability through structured interface management and analytics
- Accelerated execution across engineering, procurement, manufacturing, logistics, and construction
- Strengthened accountability and coordination across six countries and three continents
- Reduced delays and improved transparency at corporate, vendor, and site levels
- 30% reduction in procure-to-pay lead time
- 20% reduction in purchase order delays
- 167 critical path barriers mitigated or eliminated
Our Approach
EFESO implemented a structured, data-driven approach combining Lean Construction, predictive analytics, and interface management:
Leadership Alignment & Lean Construction Training
- Conducted global workshops to define roles, responsibilities, and expectations.
- Applied Lean Construction and pull planning for major milestones.
Global Command Center & Visual Management
- Established centralized tracking of critical path milestones and interfaces.
- Implemented daily and weekly stand-ups across all levels.
Schedule Optimization & Predictive Analytics
- Reviewed and optimized master schedule, reducing total schedule by 12% and costs by 3%.
- Developed project control dashboards for transparent tracking from corporate to vendor level.
- Applied Critical Path Analytics to align activities and minimize delays.
Interface Management & Risk Mitigation
- Standardized interfaces between engineering, manufacturing, logistics, customs, and construction.
- Identified and mitigated 167 critical path barriers to improve predictability.
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.
Digital & AI
Digital investments fail to deliver operational impact. We translate technology into performance gains through practical AI deployment, data-driven decision systems, and frontline digital tools.
Lean Lab
Volatile workloads create productivity troughs and lead-time peaks. We stabilize lab operations through capacity modeling, dynamic resource allocation, and lean process optimization.
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.
Procurement
Material costs and supplier volatility threaten profitability. We unlock savings through strategic sourcing, supplier collaboration, and digital procurement transformation.
Looking to Accelerate Complex Global Projects?
- Struggling with cross-functional coordination across multiple countries?
- Facing schedule delays and cost overruns in large-scale CapEx programs?
- Seeking greater visibility and predictability in complex project execution?
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