We combine deep industrial expertise with private equity insight to drive real results. We future-proof your business with concrete, tailored and impactful consulting services. A large industrial bakery was experiencing significant operational inefficiencies that limited productivity, increased costs, and constrained overall plant performance. Industry: Food & Beverage A large North American industrial bakery with approximately 1,000 employees and seven production lines manufacturing frozen cookies, bread, muffins, ready-to-eat cookies, and flatbread products. 1K employees 7 Production lines “ High levels of unplanned downtime impacting production reliability Excessive material waste and quality losses across multiple production lines Limited maintenance capability leading to prolonged equipment failures Lack of structured manufacturing systems and performance management routines Low leadership maturity and limited frontline ownership of results High hourly and temporary labor turnover Reduced engagement and sponsorship from senior leadership during portions of the transformation Operational disruptions resulting from COVID-related restrictions Real Results Achieved Together A comprehensive operational assessment identified substantial opportunities to improve Overall Equipment Effectiveness (OEE), reduce losses, strengthen management systems, and improve workforce engagement. EFESO deployed a structured WCOM Boost & Build transformation focused on loss elimination, capability development, and sustainable management systems. $2.5M 20% Transformation Impact Improved startup, changeover, and operational consistency Improved product quality and process stability >$570,000 in direct labor savings >$500,000 in food and material waste savings ~$350,000 reduction in finished goods destruction costs Performance management system embedded throughout the plant Improved leadership effectiveness and employee engagement Enhanced problem-solving capability and ownership at all organizational levels Foundation established for sustained continuous improvement Our Approach Identification of major losses related to downtime, startup and changeover performance, and quality defects Pareto-based prioritization to focus resources on the highest-value opportunities Cross-Functional Loss Reduction Teams Deployment of 7–10 focused improvement teams during each Boost cycle Direct engagement of more than 150 employees per cycle Structured problem-solving and root-cause elimination activities Performance Control System (PCS) Implementation Installation of daily management routines at line, department, and plant levels KPI-driven performance reviews and accountability processes Structured deviation management and action planning Coaching support for frontline leaders and supervisors Quality and Process Standardization Improved process consistency and product quality Reduction of variation across production lines Leadership Development Strengthening of frontline ownership, accountability, and continuous improvement capabilities Creation of sustainable management practices to support long-term performance gains Related Services Facing Similar Operational and Productivity Challenges? Improve Overall Equipment Effectiveness (OEE) and reduce losses, strengthen management systems and improve engagement Increase engagement and sponsorship from senior leadership and raise leadership maturity and frontline ownership of results Focus on loss elimination, capability development, and sustainable management systems Chemicals $1.8M 61% Food & Beverage $1M $8.5M 78% Food & Beverage $50M $15M Chemicals How we Help