10%
Increase in throughput across three sites in Europe and Asia
Global Optics Manufacturer Accelerates Throughput and Cuts Cycle Times by 40%: Performance transparency, standardization, and automation across multiple sites
Industry: Industrial Manufacturing
Service: Manufacturing
Our Client
A global optics and optical systems manufacturer generating $250 million in annual revenue, serving Aerospace & Defense, Medical & Life Sciences, and Sensors & Detection industries. Operations spanning multiple sites in Europe and Asia.
The Challenge
The client faced significant performance variability and limited operational transparency across independently managed sites:
- Lack of standardized KPIs and inconsistent data tracking
- Low machine utilization and long setup times
- Inefficient cost allocation and margin erosion
- Fragmented production controls and poor process standardization
- Limited automation and optimization in production engineering
Real Results Achieved Together
Through Lean-based standardization, process control optimization, and automation upgrades, EFESO helped the client enhance visibility, efficiency, and profitability across global sites.
40%
Reduction in cycle times for high-volume products
18
Department-level Gemba and shop floor management systems deployed
Transformation Impact
- Standardized KPIs and management systems across all sites.
- Improved profitability through accurate cost allocation and production control.
- Enhanced visibility, automation, and process stability.
- Built a foundation for scalable, data-driven operational excellence.
Our Approach
EFESO implemented a multi-site operational transformation to enhance visibility, efficiency, and profitability through standardized systems, Lean practices, and automation.
Standardizing KPIs and Management Systems
- Introduced visual management tools, dashboards, and structured management routines.
- Aligned daily shop floor metrics with global reporting standards for transparency and accountability.
Production Control and Cost Allocation Optimization
- Implemented barcode scanning for accurate tracking and cost allocation.
- Enhanced profitability analysis to address margin erosion and improve decision-making.
Machine Utilization and Setup Time Reduction
- Installed real-time downtime monitoring and reporting tools.
- Conducted Kaizen workshops to reduce setup times and increase machine availability.
Enhanced S&OP and Capacity Planning
- Developed standardized capacity and forecasting tools.
- Optimized SAP parameters to improve demand planning accuracy and responsiveness.
Automation and Cycle Time Reduction
- Upgraded tooling design and automation systems.
- Achieved up to 40% cycle time reduction while improving process stability and product quality.
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Facing Similar Challenges?
- Improve production visibility and performance control across sites.
- Reduce cycle times through Lean optimization and automation.
- Build a scalable management system that drives continuous improvement.
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