45
Manufacturing sites
An OpEx Program for a Cosmetics Company Delivers +15% in OEE
A global beauty and cosmetics leader partnered with EFESO to accelerate its operational excellence journey and embed a continuous improvement culture across its global manufacturing network.
By deploying a structured WCOM/TPM program and implementing digital daily performance systems, the company achieved a +15% increase in OEE within two years, while strengthening cross-functional teamwork and analytical capabilities.
Service: Operational Excellence
Our Client
The client is a global leader in the cosmetics and beauty industry, with a vast industrial and R&D footprint encompassing 45 manufacturing sites and 18 research centers worldwide. Employing over 77,000 people across more than 150 nationalities, the company drives innovation and excellence to deliver a diverse portfolio of beauty products to consumers around the globe.
+70K
Employees
€20B+
Annual turnover
The Challenge
The client needed to promote World Class Manufacturing and Total Productive Maintenance (TPM) as a way of life across all its global production sites. The key objective was to drive a continuous improvement culture centered on standardization and daily performance control to improve efficiency and competitiveness in a volatile demand environment.
Key challenges included:
- Low OEE performance caused by frequent breakdowns, short stops, and quality losses on packaging lines
- Lack of standardization and consistent use of daily performance systems across sites
- Need to strengthen cross-functional collaboration between production and maintenance teams
Real Results Achieved Together
The program delivered substantial improvements in efficiency and performance management, while embedding a strong cross-functional culture within the production organization. The initiative not only improved OEE performance but also drove a cultural shift towards proactive problem-solving and shared accountability across production and maintenance teams.
+15%
OEE increase
Transformation Impact
- Loss deployment identified and addressed in breakdowns, short stops, and quality issues
- Digital Daily Performance Meetings implemented in production and maintenance
- New standardized PM and PCS practices across all factories
- Strengthened cross-functional collaboration and analytical skills
Our Approach
EFESO supported the client and the Operations Director in deploying a structured, data-driven program focused on efficiency improvement, standardization, and cultural change.
Key steps included:
- Pilot Phase: Deep loss intelligence analysis to identify key loss areas on packaging, labeling, and capping machines at the pilot factory.
- Performance Control System (PCS): Development and implementation of a daily performance control system integrating production and maintenance.
- Standardization: Creation of standard preventive maintenance (PM) routines and PCS practices to ensure consistency across departments.
- Global Roll-out: Deployment of the pilot approach across all factories within the group to scale results and sustain improvements.
