12
sites worldwide
Driving Operational Excellence Across 12 Global Chemicals Sites
Industry: Chemicals
Service: Manufacturing
Service: Operational Excellence
Service: Operations Strategy and Transformation
Our Client
A global specialty chemicals producer operating 12 sites across the Americas, EMEA, and APAC, with a history of growth through acquisitions. The company combines strong international presence with extensive operational capabilities in manufacturing specialty chemical products.
The Challenge
Following acquisitions and organizational changes, the client needed to:
- Integrate heritage organizations: Harmonize two distinct cultures and ways of working across all sites
- Improve profitability: Deliver both short-term results and increase long-term organizational maturity
- Establish a common production system: Facilitate site integration, knowledge exchange, and a unified Operational Excellence approach
- Harmonize Maintenance & Manufacturing: Standardize and professionalize work practices
- Create sustainable infrastructure: Embed continuous improvement capabilities across all operations
- Deliver substantial financial impact: Original ambition of ~€40M recurring annual EBITDA
Real Results Achieved Together
EFESO guided the client through a multi-site Operational Excellence program, achieving measurable financial benefits while fostering a cohesive and skilled operations community.
€67M
annual benefits achieved
450
individuals trained in OPEX topics
€120M
value potential identified
Transformation Impact
- Developed a client-specific production system across 12 sites
- Trained individuals to lead Operational Excellence initiatives, with broader training reaching 2,570+ employees
- Delivered 26% fixed cost reduction, 8% variable cost improvement, and 66% additional margin potential
- Created sustainable infrastructure including Autonomous Management, Focused Improvements, and Planned Maintenance pillars
- Built communities of practice to facilitate collaboration and continuous improvement across all sites
Our Approach
EFESO implemented a structured, phased methodology:
- Global scans: Assess 12 sites to validate benefits and identify quick wins
- Site-specific roadmaps: Develop customized plans for Operational Excellence deployment
- Client-specific production system: Design and roll out to all sites
- Organizational blueprint for maintenance: Standardize roles and processes globally
- BOOST, BUILD, Continuous Improvement: Pilot wave sites, then scale to remaining operations
- Pillar structure implementation: Establish Autonomous Management, Focused Improvements, and Planned Maintenance with trained Process Kaizen Engineers
- Capability building: Hands-on coaching and structured training programs for hundreds of employees
This approach ensured rapid value realization while embedding a unified culture of Operational Excellence.
Related Services
Manufacturing
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Operations Strategy and Transformation
Helping organizations rethink how they create value. We strengthen performance, build resilience, and accelerate growth across every layer of your business.
Ready to Transform Your Global Operations Into a Unified Excellence Engine?
- Unlock sustainable value across your entire manufacturing network through proven operational excellence
- Stop struggling with fragmented systems and inconsistent performance across your sites
- Join global leaders who've built world-class production systems that deliver year after year
Discover More Clients Results
+20%
OEE improvement
Food & Beverage
Operational Excellence in the Beer Sector
Global brewer transforms 150 breweries through customized OpEx program, achieving €400M savings and doubled productivity.
+8.3%
OEE increase in 3 months
Packaging
WCOM™ Boosts OEE 8.3% in 3 Months in Forestry & Paper
Board manufacturer increased production capacity through WCOM™ implementation, achieving 8.3% OEE improvement in three months.
+20%
Increase in global production capacity using the same plants
Life Sciences
WCOM™ Boosts Production Capacity 20% and OEE 12% in Cosmetics
Global cosmetics manufacturer implements WCOM™ across 29 plants, achieving 20% capacity gain and 70% OEE.
-55%
Waste reduction (from 12.5% to 6.8%)
Packaging
WCOM™ Cuts Waste 55% and Delivers Savings in Packaging
Packaging manufacturer slashes material waste by 55% through WCOM™ defect analysis and machine care protocols.
-50%
Reduction in claims
Packaging
WCOM™ Implementation that Transforms Global Packaging Performance
Global packaging manufacturer deploys WCOM™ across 24 plants, slashing claims and waste 50% while boosting productivity 30%.
+20%
Production capacity
Packaging
WCOM Implementation Increases Production Capacity by 20% and Reduces Accidents by 75%
Building operational excellence at a major sawmill in Sweden, increasing production capacity by 20% and reducing accidents by 75%.
+30%
OTIF improvement
Life Sciences
WCOM™ in a Global Provider of Services to Pharma
Reengineered Order Management processes for pharma services provider, achieving 30% OTIF improvement to 95% target.
60%
Reduction in start-up time
Food & Beverage
Vertical Start-Up Reduces CAPEX Project Time by 60%
Accelerated CAPEX execution through Vertical Start-Up methodology, reducing project timelines by 60% across European operations.