+$11B
Annual revenues
New Maintenance Organization Delivers $300K Annual Savings in Chemicals
A specialty polymers site within a global chemical company partnered with EFESO to redesign and implement a new maintenance organization. The goal: increase efficiency, improve Work Order processes, embed a culture of continuous improvement, and deliver €2.1M in benefits over three years.
Industry: Chemicals
Service: Manufacturing
Service: Operational Excellence
Service: Operations Strategy and Transformation
Our Client
The Specialty Polymers site of a major chemical company generating more than $11 billion in revenue and over $2 billion in EBITDA, highlighting strong financial stability and solid competitive positioning within the industry.
+$2B
EBITDA
The Challenge
- Design, review and implement a new functional organization in the Maintenance department
- Increase efficiency via a structured methodology to manage Work Order Process and maintenance activities
- Bottom line benefits objective of $2.5M in three years
Real Results Achieved Together
The transformation delivered measurable financial and organizational impact, strengthening maintenance performance and operational efficiency across the site.
$300K
Annual benefits achieved
100
Employees aligned under new maintenance structure
3
Maintenance areas fully redesigned and implemented
Transformation Impact
- New organizational structure, roles, responsibilities, KPI framework, and meeting cascade implemented across all three maintenance areas
- PCS tools and methodologies installed, validated, and coached daily
- Significant cost savings achieved through operational efficiency improvements and contractor renegotiations
- Strong local ownership enabled through change-agent coaching and empowerment
Our Approach
- Review and enhance the internal Maintenance Excellence methodology, aligning it with local current and future organization
- Define and validate the 1.5-year tactical implementation plan, generating local buy in and empowering local change agents
- Manage and coordinate the critical ramp up phase of implementation, providing coaching to maintenance team and to change agents (coach-the-coach approach)
- Support site management team in developing and embedding the required continuous improvement culture, and coach its use and dissemination
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Ready to Transform Your Maintenance Operations Into a Strategic Asset?
- Unlock hidden capacity and reduce costs through optimized maintenance excellence
- Stop losing value to inefficient processes and outdated organizational structures
- Join chemical industry leaders who’ve achieved sustainable operational transformation
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