+€10B
Annual revenues
New Maintenance Organization Delivers €260K/Y in Chemicals
A specialty polymers site within a global chemical company partnered with EFESO to redesign and implement a new maintenance organization. The goal: increase efficiency, improve Work Order processes, embed a culture of continuous improvement, and deliver €2.1M in benefits over three years.
Industry: Chemicals
Service: Manufacturing
Service: Operational Excellence
Service: Operations Strategy and Transformation
Our Client
The Specialty Polymers site of a major chemical company generating more than €10 billion in revenue and over €2 billion in EBITDA, highlighting strong financial stability and solid competitive positioning within the industry.
+€2B
EBITDA
The Challenge
- Design, review and implement a new functional organization in the Maintenance department
- Increase efficiency via a structured methodology to manage Work Order Process and maintenance activities
- Bottom line benefits objective of 2.1M€ in three years
Real Results Achieved Together
The transformation delivered measurable financial and organizational impact, strengthening maintenance performance and operational efficiency across the site.
€260K
Annual benefits achieved
100
Employees aligned under new maintenance structure
3
Maintenance areas fully redesigned and implemented
Transformation Impact
- New organizational structure, roles, responsibilities, KPI framework, and meeting cascade implemented across all three maintenance areas
- PCS tools and methodologies installed, validated, and coached daily
- Significant cost savings achieved through operational efficiency improvements and contractor renegotiations
- Strong local ownership enabled through change-agent coaching and empowerment
Our Approach
- Review and enhance the internal Maintenance Excellence methodology, aligning it with local current and future organization
- Define and validate the 1.5-year tactical implementation plan, generating local buy in and empowering local change agents
- Manage and coordinate the critical ramp up phase of implementation, providing coaching to maintenance team and to change agents (coach-the-coach approach)
- Support site management team in developing and embedding the required continuous improvement culture, and coach its use and dissemination
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 Maintenance Operations Into a Strategic Asset?
- Unlock hidden capacity and reduce costs through optimized maintenance excellence
- Stop losing value to inefficient processes and outdated organizational structures
- Join chemical industry leaders who've achieved sustainable operational transformation
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.