Industry: Automotive and Commercial Vehicles
Service: Cost and Value Engineering
A mid-sized European automotive supplier with over two thousand employees. The company specializes in electrical and electronic modules, with expertise spanning R&D to scaled manufacturing, particularly e-mobility system components for passenger cars.
+2K
Employees
~€900M
Annual revenue
The supplier aimed to quote a high-voltage battery module for a premium OEM’s next-generation vehicle program, representing 1.5 million units over the product lifetime. Key challenges included:
EFESO’s engagement delivered measurable and longer-term benefits despite the OEM reallocating investments unrelated to this project.
16–23%
Potential cost savings identified on key bill of materials components
+100
Line items included in the Greenfield cost model
1.5M
Units in OEM program analyzed for cost modeling
EFESO deployed a three-step methodology:
Speed and transparency aligned management and teams; external expertise offered verification and alternative perspectives; documentation was structured for reuse in future tenders and internal business cases.
Rising costs demand optimization from design through production. We apply cross-functional value engineering, zero-based redesign, and continuous cost tracking to protect margins.
60%
Reduction in start-up time
Food & Beverage
Accelerated CAPEX execution through Vertical Start-Up methodology, reducing project timelines by 60% across European operations.
$2.5M+
Procurement savings secured
Industrial Manufacturing
Private Equity
Scientific instruments manufacturer faced production bottlenecks and quality challenges. We redesigned manufacturing flow, implemented lean principles, and enhanced testing protocols, improving on-time delivery to 95%.
€636K
Validated savings achieved
Life Sciences
Packaging
Packaging manufacturer achieved €636K savings through optimized labor ratios, reduced scrap, and material efficiency improvements.
$14.5M
EBIT improvement achieved
Food & Beverage
Private Equity
Agricultural producer needed productivity improvement and waste reduction. We optimized growing processes, automated harvesting operations, and enhanced quality control, increasing yield by 25%.
Industrial Manufacturing
Fact-based restructuring of a complex industrial site, enabling a clear shutdown decision, cash-drain elimination, and a structured roadmap for execution.
-30%
Inventory cost reduction
Transportation, Logistics and Services
Cruise operator required operational excellence across fleet operations. We optimized crew efficiency, enhanced maintenance planning, and improved supply chain logistics, reducing operating costs by 12%.
10-12%
Reduction in overall system costs
Industrial Manufacturing
Oil & Gas, Sustainable Energy
Industrial cooling systems provider faced operational complexity post-acquisition. We integrated operations, standardized processes, and optimized production planning, improving delivery performance by 45%.
30-40%
Savings achieved
Life Sciences
Pharmaceutical manufacturer reduces production costs 30-40% while preparing operations for 2027 capacity expansion and growth.
