EFESO COST REDUCTION PROGRAM

Cost reduction programs are both a sprint and a marathon. Many initiatives start with high ambitions, but underestimate the hurdles of implementation. As a result, successes are short-term at best and are not reflected in the profit and loss statement (P&L).

EFESO offers a tried and tested approach to optimizing cost structures along industrial value chains, which combines rapidly effective cost savings with a sustainable streamlining of your processes. In doing so, we are guided by three criteria with which we secure the performance and further development of your value creation processes in the long term:

  • Process excellence: the central driver for the cost base.
  • Flexibility: those operating in volatile markets must be able to respond to sales fluctuations or new, competitors at any time.
  • Resilience: cost reduction programs must specifically take disruptions such as interrupted supply chains into account.

 

AUTOMOTIVE SUPPLIER

Project: Product cost reduction in the business unit of a family-owned company (1 billion turnover worldwide p.a.). Holistic cost reduction programme to stop losses and sustainably improve processes and organisation.

Results: Introduction of a shopfloor management as well as production planning led to a

  • Productivity increase of 22% in the direct and indirect areas
  • Reduction of backlog by almost 100% 
  • Reduction of internal defect costs by more than two thirds
  • Introduction of premium wages
  • Reduction of consumables by 10%
  • Increase in inventory turnover rate by 40% 


The implementation of a one-piece flow on the assembly line resulted in an increase in the

  • EBIT margin by +8.5%
  • EVA margin by +7% after one year.

 

3-step Approach – EFESO Cost Reduction Approach

Our experts develop a customized cost reduction program for your organisation that delivers both levers for fast-acting savings effects and effective long-term improvement measures.

In an integrated top-down/bottom-up approach, we first identify and evaluate the cost and expense drivers along your value chain and in indirect
areas. We then derive suitable measures to realize the identified cost reduction potentials and accompany their implementation in agile sprints. Through continuous monitoring and bridging of the savings potential into the income statement, we ensure the success of implementation and the effectiveness of the measures in the balance sheet.

CONTACT

  

Dr. Michael Breitling

Dr. Michael Breitling
Expert Director

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Ahmed Sahyoun

Ahmed Sahyoun
Expert Partner

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Dr. Thomas Troll

Dr. Thomas Troll
Senior Partner

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CASE STUDIES - PRACTICAL EXAMPLES

Close-up einer Maschine
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Case studies

A plant and mechanical engineering company had to ensure its competitiveness. EFESO identified all the adjustment screws for the necessary changes at a production site in Germany and got the turnaround going with a multi-layered restructuring approach.

Zero-Based-Organisation
Case studies

Champions do not rest contentedly with their success, but always have their sights set on the next milestone. A technology group with around 20,000 employees at over 16 locations worldwide is also orienting itself in the direction of such a “North Star”. His starting points: an operational strategy and the initiatives derived from it, which should be implemented at every location in order to make them even more efficient.

VALUE AND COST ENGINEERING
Case studies

Cost transformation from premium to volume provider. Mass manufacturers who expand their Product portfolio into higher price segments are not uncommon. A premium manufacturer of refrigeration appliances, on the other hand, takes the opposite approach. What seems banal from a technological point of view is an enormous challenge from a cost perspective. EFESO accompanied the company in this demanding transformation project.

Case studies

With hard targets for the entire operations area, a valve manufacturer is aligning a plant location for the future - and thus securing the site in Germany. Together with EFESO, the company restructures its manufacturing and logistics and achieves, among other things, an OEE of more than 85%.