$16M
Annual pre-tax earnings improvement
Operational Excellence at a Chemical Plant: Driving Cost Reduction and Reliability Improvements
Industry: Chemicals
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: People and Organization
Our Client
A chemical manufacturing company under extreme cost pressures, seeking to improve EBITDA through operational efficiency, reliability, and sustainable continuous improvement.
The Challenge
The plant faced urgent cost pressures and operational inefficiencies affecting reliability and performance. There was no structured performance management, unclear accountability, and no institutionalized continuous improvement culture, limiting EBITDA and operational effectiveness.
- High cost pressures: Urgent need to reduce costs and improve EBITDA.
- Operational inefficiencies: Processes and workflows were inconsistent, affecting plant performance.
- Limited accountability: Lack of structured performance management and KPI tracking.
- Weak continuous improvement culture: Operational teams were not fully engaged in maintaining or improving processes.
Real Results Achieved Together
The chemical plant achieved substantial operational and financial improvements, with enhanced process reliability and strengthened team accountability.
50%
Increase in truck loading efficiency
100%
adherence to weekly load schedule (vs daily scheduling)
Transformation Impact
- Manpower utilization increase from 40% to 90%
- Schedule attainment improved from 42% to 86%
- Priority 1 incidents reduced from 40% to 10%
- Embedded KPI-driven management to strengthen accountability and drive sustainable improvements.
- Applied Lean principles across operations and support functions, generating measurable cost and efficiency gains.
- Built ownership among operational teams, resulting in lasting reliability improvements.
- Improved schedule adherence, manpower utilization, and overall operational reliability.
- Enhanced maintenance and workflow processes, reducing production disruptions and P1 incidents.
Our Approach
EFESO implemented a structured approach combining leadership development, performance management, and Lean-based process improvements.
Leadership & Performance Management
- Coached leaders to drive continuous improvement and operational excellence.
- Implemented a KPI-driven Performance Management Operating System to improve visibility and accountability.
Best Practices Implementation & Ownership
- Deployed optimized operating models and defined clear roles and responsibilities.
- Introduced Continuous Improvement frameworks and Visual Management to track performance in real time.
Operational Effectiveness & Reliability Improvements
- Transferred workflow ownership to operational teams.
- Strengthened maintenance and reliability strategies, including Leader Walks and Operator-Driven Maintenance.
- Consolidated soft crafts and applied metric-driven contractor productivity.
- Applied Lean methods to improve efficiency in laboratory, truck loading, and warehouse operations.
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Facing Similar Challenges?
- Reduce costs and improve EBITDA through operational excellence.
- Strengthen accountability and ownership across plant operations.
- Embed sustainable continuous improvement practices.
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