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Global Chemical Manufacturer Saves $8.5M Through an Operational Excellence Transformation

A global chemical manufacturer operating more than 15 facilities on three continents faced several operational and performance challenges needed a scalable solution to address issues and support sustainable global growth

Industry: Chemicals

Service: Manufacturing

Service: Operational Excellence

Service: Operations Strategy and Transformation

Parallaxe

Our Client

A leading global specialty chemicals manufacturer operating more than 15 production facilities across North America, Europe, and Asia-Pacific, employing over 1,500 people and generating approximately $1.8 billion in annual revenue.

15

production facilities across North America, Europe, and Asia-Pacific

1.5K

employees worldwide

$1.8B

Annual revenue

“

The program was instrumental in sustaining performance during a challenging economic environment. By building robust operating methods and internal capabilities, it created a foundation for long-term competitiveness, resilience, and continued improvement.

“
Parallaxe

The Challenge

The client faced several operational and performance challenges across its global manufacturing network:

  • Persistent equipment reliability and mechanical integrity issues driving unplanned downtime
  • High utilization and availability losses limiting production capacity
  • Significant quality losses caused by off-specification product and process variability
  • Escalating demurrage and logistics-related costs
  • High workforce turnover creating training and capability gaps
  • Inconsistent performance management systems across sites
  • Need for a scalable operational excellence framework to support sustainable global growth

Real Results Achieved Together

Through EFESO's deployment of World Class Operations Management (WCOM) methodology, the client was able to perform a data-driven opportunity assessment, a global boost & build deployment, increased capability development and improve governance and sustainability.

$8.5M

Annualized savings

12%

improvement in asset utilization

8%

increase in Overall Equipment Effectiveness

4%

reduction in fixed operating costs

Transformation Impact

  • Executive sponsorship supported by a robust global governance model
  • Standardized methodology deployed consistently across multiple regions
  • Strong focus on internal capability development and leadership ownership
  • Structured loss elimination approach targeting the largest value opportunities
  • Sustainable systems and behaviors embedded to maintain performance gains
Parallaxe

Our Approach

EFESO partnered with the client to design and deploy a global WCOM transformation program across six manufacturing sites.

Data-Driven Opportunity Assessment

  • Conducted comprehensive loss analyses using EFESO’s Factory Model methodology
  • Quantified improvement opportunities across reliability, quality, productivity, and cost performance
  • Established baseline performance and site-specific value creation targets

Global Boost & Build Deployment

  • Developed a multi-year transformation roadmap tailored to each site’s maturity level
  • Executed a staggered implementation across six facilities over 24 months
  • Balanced rapid performance improvements with long-term capability development

Capability Development

  • Trained and coached site leadership, WCOM champions, and Process Kaizen Engineers
  • Established structured Loss Reduction Teams focused on the highest-value opportunities
  • Embedded continuous improvement methodologies into daily operations

Governance & Sustainability

  • Co-created a global governance structure with executive leadership
  • Standardized best-practice sharing across regions
  • Built internal ownership through leadership development and system deployment
  • Transitioned from program-driven improvements to self-sustaining management systems

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Parallaxe

Facing Similar Operational and Performance Challenges?

  • Boost improvement opportunities across reliability, quality, productivity and cost performance,
  • Reduce training and capability gaps caused by workforce turnover through training and coaching site leadership
  • Create and implement a global governance structure and standardized best practices shared across regions
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