Client: EFESO Management Consultants, supporting a large international manufacturing client
Project: Digital Scan for Loss Reduction
Objective: Identify high-value, easily executable digital solutions to reduce operational losses

Challenge:
The manufacturing client, with facilities across the globe, sought to reduce production losses and improve operational efficiency. To address this, EFESO Management Consultants engaged BouL and its founder, Roeland Kuipers, to conduct a comprehensive digital scan. The goal was to pinpoint actionable digital initiatives that could be implemented to drive measurable improvements, starting with two strategic “lighthouse” factories in Italy and Germany.

Solution:
The digital scan kicked off with an in-depth GEMBA walk of the production lines, allowing BouL to observe daily operations firsthand. Roeland collaborated closely with line operators and key departments, including engineering, maintenance, and planning, conducting interviews to understand pain points and bottlenecks directly from the team members involved.

This fieldwork was followed by collaborative workshops to engage stakeholders in identifying digital use cases that offered the highest value and were easiest to implement. The workshops focused on aligning perspectives from various departments, ensuring that the solutions selected would have both strategic impact and practical feasibility.

Impact:
Through this human-centered approach, BouL identified high-impact, achievable digital use cases that addressed specific challenges within each lighthouse factory. This created a roadmap for loss reduction that was both tailored to the unique operations of the Italian and German facilities and supported by the departments that would carry it forward. And at the same time looked at scalable use-casas which could apply to the operation globally.

Results:

• Comprehensive digital scan conducted at two key facilities

• High-value, easy-to-execute digital use cases identified

• Enhanced cross-departmental alignment for sustainable implementation

By combining technology with a deep understanding of daily operations, BouL’s digital scan provided EFESO’s client with a clear, practical roadmap to reduce operational losses and boost efficiency across its European factories.