Discover how EFESO works side by side with clients across industries to achieve measurable, lasting impact. Each story captures the challenges our clients faced, the actions we took together – from boardroom to shop floor – and the tangible operational and financial results delivered.
40%
Reduction in Capital Expenditures for new production technology
Packaging
Manufacturing
Operational Excellence
A leading global manufacturer of glass containers reduce capital expenditure by 40% in the commercialization of a new glass production technology by applying Value Engineering and Lean Product Development principles.
13%
Reduction in release time for high-value APIs
Chemicals
Life Sciences
Manufacturing
Operational Excellence
Smart Factory
A QC lab optimization framework helps a multinational chemical-pharmaceutical company achieved simultaneous gains in productivity, service level, and resource efficiency, delivering measurable improvements in release time, productivity, and FTE requirements without compromising quality.
60%
Reduction in lead time
Life Sciences
Manufacturing
Operations Strategy and Transformation
Supply Chain
Streamlined biotechnology contract manufacturing operations, reducing 18-24 month lead times by 60% and inventory by 45%.
15%
Reduction in indirect purchasing costs
Automotive and Commercial Vehicles
Private Equity
Manufacturing
Operations Strategy and Transformation
Procurement
Transactions and Turnaround
Industrial machinery manufacturer faced complexity in custom equipment production. We implemented modular design principles, standardized components, and optimized project management, reducing lead times by 40%.
4x
Enterprise value growth
Private Equity
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Optimized asset portfolio across seven sites, relocating production to Mexico, achieving 4x enterprise value growth.
+17%
Output increase possibility identified
Aerospace & Defense
Manufacturing
Operations Strategy and Transformation
Aerospace manufacturer increased aircraft assembly capacity 17% through operational optimization, achieving 4.2-hour takt time sustainably.
100%
Problem eradication and stable reactor operation restored
Chemicals
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Urea reactor failures slashed output by 50%. PM analysis traced root cause to upstream pump lubricant. Restored stable high performance.
+50
Smart Factory projects identified
Life Sciences
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Smart Factory
Assessed three pharma plants, prioritized 50 Smart Factory initiatives, achieving 1.4-year payback on first wave.
+50%
TIR rates improvement per year
Food & Beverage
Private Equity
Leadership & Change Management
Manufacturing
Operational Excellence
People and Organization
Harmonized post-merger manufacturing cultures through customized operating system, delivering 40% cost reduction and sustainable capabilities.
-17%
Lead time reduction
Industrial Manufacturing
Manufacturing
Operations Strategy and Transformation
People and Organization
Procurement
Supply Chain
Packaging machinery group needed lead time and inventory optimization. We conducted comprehensive value stream analysis, identified bottlenecks, and developed transformation roadmap, targeting 40% reduction potential.
8-10%
Transformation cost reduction achieved
Aerospace & Defense
Cost and Value Engineering
Digital & Ai
Manufacturing
Operations Strategy and Transformation
People and Organization
Procurement
Aerospace corporation faced fragmented digital infrastructure across divisions. We launched enterprise-wide transformation, integrated systems, and drove operational excellence, reducing operational costs by 10%.
+44%
Plant throughput increase
Food & Beverage
Private Equity
Cost and Value Engineering
Manufacturing
Operations Strategy and Transformation
Procurement
Supply Chain
Energy infrastructure operator faced aging assets and rising maintenance costs. We implemented reliability-centered maintenance, optimized turnarounds, and enhanced asset management, extending equipment life by 30%.
$2M
Expected cost savings
Industrial Manufacturing
Manufacturing
Operations Strategy and Transformation
People and Organization
Standardized global engineering processes for cooling systems manufacturer, reducing project hours 15-50% across sites.
25%
Reduction in COGS across 10 major product families
Industrial Manufacturing
Oil & Gas, Sustainable Energy
Cost and Value Engineering
Manufacturing
R&d and Product Profitability
Restructured product development and optimized designs, achieving 25% COGS reduction across ten product families.
73%
Technician efficiency observed on direct tasks
Transportation, Logistics and Services
Digital & Ai
Manufacturing
Operations Strategy and Transformation
Diagnosed bus maintenance inefficiencies, deployed Power BI performance dashboard, unlocked 28% productivity improvement worth $8-10M.
21%
Potential combined EBITDA increase
Consumer Goods and Luxury
Packaging
Cost and Value Engineering
Manufacturing
Operations Strategy and Transformation
Boosted packaging line efficiency through SMED deployment and visual management, achieving 21% EBITDA increase potential.
21%
Increase in electrician productive time
Transportation, Logistics and Services
Manufacturing
Operations Strategy and Transformation
People and Organization
Structured planning and daily performance management increased electrician productivity by 21%, achieving over 95% preventive maintenance attainment.
$6M
In annual cost savings, surpassing the $4.3M target
Transportation, Logistics and Services
Cost and Value Engineering
Manufacturing
Operations Strategy and Transformation
Rail company slashed costs by $6M and boosted on-time performance through re-engineered operations and cross-functional alignment.
98%
Preventive maintenance compliance
Oil & Gas, Sustainable Energy
Manufacturing
Operations Strategy and Transformation
People and Organization
Overcame siloed teams and change resistance through integrated maintenance structure, delivering $10M savings and 98% compliance.
40%
Reduction in overall tank workflow time
Oil & Gas, Sustainable Energy
Cost and Value Engineering
Manufacturing
Procurement
Streamlined tank management workflows at 200 Mbpd refinery, achieving 100% schedule compliance and $8M annual savings.
4x
Return on investment
Chemicals
Lean Lab
Manufacturing
Operations Strategy and Transformation
People and Organization
Standardized maintenance workflows and Lean techniques reduced emergency work orders 40-50% while increasing throughput 35%.
+20%
Increase in global production capacity using the same plants
Life Sciences
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Global cosmetics manufacturer implements WCOM™ across 29 plants, achieving 20% capacity gain and 70% OEE.
+$46M
Savings delivered
Packaging
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Sustainability
Deployed global OpEx program across 25 plants, standardizing waste reduction practices to deliver $46M savings and 4.5M tons CO₂ reduction.
15%
Increased winter capacity
Oil & Gas, Sustainable Energy
Manufacturing
Operations Strategy and Transformation
Supply Chain
Eliminated seasonal pipeline reversals through terminal modifications and routing optimization, increasing winter capacity 15% and annual income $2M.
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See how transformation happens, from boardroom to shop floor
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