25%
Reduction in COGS across 10 major product families
Idea-to-Value Approach Strengthens Competitiveness: Driving Cost Optimization and Innovation Alignment Across Global Product Lines
Industry: Industrial Manufacturing
Industry: Oil & Gas, Sustainable Energy
Service: Cost and Value Engineering
Service: Manufacturing
Service: R&d and Product Profitability
Our Client
A global leader in the pumps market operating across multiple regions, serving both standard and engineered product segments in the industrial and energy sectors.
The Challenge
Facing declining sales and profitability due to a market downturn, the client needed to enhance product competitiveness, reduce COGS, and accelerate innovation across global sites.
- Declining sales and shrinking margins amid intensified competition
- Loss of market share in standard and engineered product lines
- Fragmented global product development and limited coordination
- Designs optimized for Western markets but uncompetitive in Asia-Pacific
- No systematic design-to-cost reviews for mature products
Real Results Achieved Together
By integrating value engineering, cost optimization, and innovation governance through the Idea-to-Value framework, EFESO helped the client achieve significant operational and strategic gains.
+100
Design change proposals implemented
Transformation Impact
- Improved competitiveness and market penetration in Asia-Pacific
- Standardized global product development and collaboration processes
- Structured execution model to sustain long-term design-to-cost improvements
- Enhanced cost efficiency and product performance through systematic design optimization
- Accelerated innovation pipeline via harmonized global processes
- Improved profitability and competitiveness in growth markets
- Sustainable capability building through internal Idea-to-Value practitioner training
Our Approach
EFESO applied its Idea-to-Value methodology to align global teams, optimize product design, and build long-term capabilities for continuous improvement.
Product Development and Design Optimization
- Analyzed the innovation funnel to align global design centers.
- Transitioned from experience-based to analysis-based design using FEA.
- Conducted structured design reviews to align specifications with market needs.
Cost Reduction and Manufacturing Efficiency
- Redesigned product families for material and weight efficiency.
- Applied DFM, DFA, and DFSC principles to reduce production costs.
- Optimized casting, manufacturing, and sourcing for profitability.
Global Standardization and Market Expansion
- Re-mapped product offerings to shorten order-to-delivery cycles.
- Transferred technology and production to Best Cost Country locations.
- Implemented a global stage-gate governance model for consistency.
Sustainability & Long-Term Impact
- Trained high-potential engineers as Idea-to-Value practitioners.
- Embedded value engineering as a core competency for lasting impact.
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.
Manufacturing
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
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 Challenges?
- Struggling with fragmented global development processes
- Seeking to strengthen competitiveness in emerging markets
- Want to embed value engineering for long-term cost efficiency
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