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.
46%
Increase in tie and rail replacement productivity
Transportation, Logistics and Services
Manufacturing
Operations Strategy and Transformation
Doubled Track Laying System productivity through optimized workflows and daily performance management, achieving 46% output increase.
55%
Reduction in outage days for crossing changeouts
Transportation, Logistics and Services
Manufacturing
Operations Strategy and Transformation
Freight rail operator reduced crossing changeout outages by 55% through Lean workshops and cross-functional process optimization.
9%
Points increase in OEE
Food & Beverage
Packaging
Manufacturing
Operations Strategy and Transformation
People and Organization
Boosted OEE and throughput for private label food producer while building operational capabilities across multiple manufacturing sites.
20%
Average productivity improvement
Food & Beverage
Manufacturing
Operations Strategy and Transformation
Supply Chain
Standardized fragmented supply network operations across 22 factories, establishing common processes and governance framework.
$8M
EBITDA savings (11% of site labor costs)
Industrial Manufacturing
Packaging
Manufacturing
Operations Strategy and Transformation
Supply Chain
Transactions and Turnaround
Restructured multi-site operations and planning processes, delivering $7m EBITDA savings and 46% downtime reduction.
17%
Reduction in Line of Road failures
Transportation, Logistics and Services
Manufacturing
Operations Strategy and Transformation
Optimized maintenance workflows and frontline leadership to boost passenger car availability, reducing failures by 17%.
+30%
OTIF improvement
Life Sciences
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Reengineered Order Management processes for pharma services provider, achieving 30% OTIF improvement to 95% target.
50%
Reduction in claims
Packaging
Manufacturing
Operations Strategy and Transformation
Global packaging manufacturer deploys WCOM™ across 24 plants, slashing claims and waste 50% while boosting productivity 30%.
45%
Reduction in overall work order backlog
Transportation, Logistics and Services
Manufacturing
Operations Strategy and Transformation
Reduced transit electrical maintenance backlog by 45% through structured workload planning and daily accountability processes.
$47M
Annual pre-tax earnings improvements
Chemicals
Manufacturing
Operations Strategy and Transformation
People and Organization
Multi-site chemical operation achieved $46.9M earnings improvement through reliability programs, productivity enhancements, and asset optimization.
10%
Increase in identified OEE potential
Chemicals
Manufacturing
Operations Strategy and Transformation
Supply Chain
Transactions and Turnaround
Evaluated acquisition targets and brownfield expansion opportunities, identifying 10% OEE improvement potential through logistics optimization.
8%
Annual capacity improvement in one process area
Chemicals
Manufacturing
Operations Strategy and Transformation
Supply Chain
Optimized production processes and S&OP implementation delivered 8% capacity gains without additional labor investment.
10%
Increase in project delivery capacity and time-to-market
Chemicals
Manufacturing
Operations Strategy and Transformation
R&d and Product Profitability
Catalyst manufacturer accelerates commercialization through Lean Product Development, achieving 10% faster delivery and $22.5M revenue gain.
$10M
Business value generated from hauler uptime improvements
Oil & Gas, Sustainable Energy
Cost and Value Engineering
Lean Lab
Manufacturing
Operations Strategy and Transformation
Coached CI practitioners using Kaizen methodology to eliminate capacity constraints, achieving $150 million in savings.
40%
Reduction in craft workforce with increased productivity
Oil & Gas, Sustainable Energy
Cost and Value Engineering
Lean Lab
Manufacturing
Operations Strategy and Transformation
People and Organization
Applied Lean methodologies to petrochemical maintenance operations, reducing craftsmen by 40% while boosting productivity 360%.
$9.7M
Annual pre-tax earnings improvement (+12%)
Chemicals
Manufacturing
Operations Strategy and Transformation
Reactive maintenance plagued chemical plants. EFESO deployed reliability-centered strategies. Achieved $9.7M earnings improvement, 75% emergency reduction.
$83M
Revenue increase with no additional capital investment
Chemicals
Manufacturing
Operations Strategy and Transformation
World-class performance management exposed hidden inefficiencies, unlocking $83M revenue growth without capital investment.
$16M
Annual pre-tax earnings improvement
Chemicals
Manufacturing
Operations Strategy and Transformation
People and Organization
Deployed operational excellence playbook at chemical plant, achieving $15.6M earnings improvement and 90% manpower utilization.
15%
Throughput improvement across four processing sites
Food & Beverage
Manufacturing
Operations Strategy and Transformation
Supply Chain
Optimized warehouse network design and TMS deployment delivered 39% capacity increase for protein processor.
20%
Reduction in Locomotive Dwell Time (LDT)
Transportation, Logistics and Services
Manufacturing
Operations Strategy and Transformation
People and Organization
Railroad operator transformed maintenance operations through EFESO system, achieving 57% reliability improvement and 2.3x throughput increase.
$11M
EBITDA improvement via operational enhancements
Life Sciences
Manufacturing
Operations Strategy and Transformation
Procurement
Supply Chain
Transactions and Turnaround
Integrated bio-tech acquisition, optimized manufacturing and supply chain operations, delivered $11.2M EBITDA improvement and $13M cash impact.
$2.7M
Cost savings from supplier diversification and freight optimization
Life Sciences
Cost and Value Engineering
Manufacturing
Procurement
Supply Chain
Medical device manufacturer diversified suppliers across four countries, optimized operations, achieving $2.7M savings and 22% inventory reduction.
$5.5M
EBITDA Savings
Life Sciences
Lean Lab
Manufacturing
Operations Strategy and Transformation
People and Organization
Harmonized six pharmaceutical sites through Lean Lab and TPM, achieving 42% downtime reduction and €4.7M savings.
60
Good Manufacturing Practices (GMP) deviations addressed
Life Sciences
Manufacturing
Operations Strategy and Transformation
Transactions and Turnaround
Resolved 60 GMP violations and critical safety risks, enabling compliant operations and successful company sale.
Discover measurable outcomes achieved with our clients
See how transformation happens, from boardroom to shop floor
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