+100
Countries of operation
Global Maintenance Excellence Delivers $58M+ Annualized Benefits
Industry: Chemicals
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: People and Organization
Our Client
A global specialty chemicals leader operating in over 100 countries with more than 33,000 employees. The company provides specialty chemical solutions across multiple industries worldwide.
+33K
Employees worldwide
The Challenge
The client faced several critical challenges:
- Harmonization of maintenance: Need to standardize maintenance practices across the 17 largest sites in the network
- Strengthening the ONE TEAM mindset: Improve collaboration between Technical Service and Business teams
- Sustainable transformation: Implement autonomous infrastructure to ensure continuous improvement
- Asset reliability and cost management: Drive improvements in maintenance efficiency and reduce overall spend
Real Results Achieved Together
EFESO’s program delivered measurable financial benefits while embedding a culture of operational excellence and collaboration across the client’s maintenance function.
25%
Efficiency gain on FTEs
55%
Reduction in technical production losses
+$58M
Annualized benefits achieved
Transformation Impact
Maintenance:
- Estimated efficiency gain for site 1: 20-25% on FTEs → $2M (to be negotiated with sub-contractors)
- Estimated efficiency gain for site 2: 12-15% (internal) 15-17% (subcontractor) → $490K-$580K
Reliability:
- Site 1: Estimated reduction of the technical production losses by 30-40% (product 1) and 40-55% (product 2)
- Site 2: Estimated reduction of the technical production losses by 35-47% (line 1) and 40-48% (line 2)
Our Approach
1st step, Rapid Assessment on two sites. The objectives were:
- To assess value creation levers
- To identify key opportunities & high-level roadmap
- To support go/no go decision for operations improvements
2nd step, Operations Analysis on two sites. The objectives were:
- To determine and quantify opportunities (business case)
- To align strategy with top and middle management
- To detail the roadmap by workstream
The next step would be to implement the defined roadmap on the two sites where the operations’ analysis was made.
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Ready to unlock hidden value in your maintenance operations?
- Transform maintenance from a cost center to a competitive advantage
- Stop losing millions to unplanned downtime and inefficient processes
- Join global leaders who’ve achieved sustainable operational excellence
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