80+
Countries
Full Production System Delivers More than $6M Savings in Pharma
Industry: Life Sciences
Service: Manufacturing
Service: Operational Excellence
Our Client
A multinational Life Sciences company with operations in over 80 countries, employing more than 100,000 people worldwide. The company generates $55 billion in annual sales and invests $8 billion in R&D each year. This project covered two of its key manufacturing sites.
+100K
Employees
$55B
Sales
$8B
Investment in R&D
The Challenge
The client faced increasing cost and efficiency pressures due to decreasing margins and unsteady production performance. A previous attempt to implement a production system had not proven sustainable, resulting in high unplanned downtime, variability in changeover times, and product defects.
The challenge centered on:
- Re-establishing a sustainable and effective production system
- Stabilizing performance across formulation and packaging lines
- Embedding accountability and ownership on the shop floor through leadership development
Real Results Achieved Together
Through the successful deployment of the full production system, EFESO and the client achieved sustainable operational improvements and measurable financial results. By embedding servant leadership and a robust production system structure, the organization achieved sustained operational discipline and performance stability across its manufacturing network.
+$6M
Savings achieved
20
Formulation and packaging lines addressed
Transformation Impact
- Successfully addressed 20 formulation and packaging lines, resulting in substantial savings exceeding $6 million
- Achieved stabilization of operational processes and notable improvements in performance KPIs
- Facilitated a transition to servant leadership behavior, fostering true ownership and accountability on the shop floor
- Effectively integrated pillar teams into the organization, driving and sustaining the production system
Our Approach
- Implementation Approach
- Tailored training concept with practical exercises for operative leaders and operators
- Implementation support with daily presence on the shopfloor (we do you do)
- Ensuring methods usage through Process Confirmations & Daily Shopfloor Management
- Leadership Development
- Set-up of new Line Leadership structure
- Coaching to support leaders and to practice Servant Leadership culture on the shopfloor
- Pillar Organization
- Implementation of local pillar teams as owners and ambassadors of pillar methods
- Strategy deployment and alignment between site business targets and production system
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Ready to Transform Your Production System Into a Sustainable Competitive Advantage?
- Achieve operational excellence that sticks—not just another failed implementation
- Stop watching your margins shrink while production struggles with unplanned downtime and inconsistent performance
- Join multinational leaders who’ve built true ownership and accountability on their shop floor
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