A global nonwovens producer supplying products for baby diapers, feminine hygiene, and construction applications was struggling with inconsistent operational performance across its sites. A Private Equity (PE) firm had acquired the company and, dissatisfied with its results, engaged Caravel Solutions to implement a global Operations Excellence (OPEX) transformation, including integration of new acquisitions.

The portfolio consisted of sites originally operated as separate companies, each with different standards, systems, and management practices. Operations, maintenance, and reliability were largely reactive, and supply chain planning lacked coordination. The client sought to establish a standardized, high-performance operating platform that could drive measurable profitability improvements and serve as a scalable system for future roll-up acquisitions.

Caravel Solutions deployed its proven Operations Excellence framework to benchmark all sites globally and identify opportunities for improvement. More than $40 million per year in potential profitability gains were uncovered.

A model site benchmark standard was developed to serve as the blueprint for global alignment, incorporating:

• Standardized organizational design and staffing expectations

• Clearly defined roles, responsibilities, and work processes

• Technology and equipment condition baselines

• Best-practice operations, maintenance, and reliability models

Each facility was assessed against this model, considering its technology, maturity, and workforce capability. Caravel then developed tailored goals and action plans for every site, monitored through a newly created internal OPEX organization.

Caravel implemented a pilot OPEX program at four sites, training internal teams to sustain and expand the initiative. Following the successful pilots, Caravel supported the integration of two new acquisitions in North and South America using the same benchmark-based framework, ensuring seamless assimilation into the standardized operating platform.

The transformation delivered an EBITDA impact exceeding $40 million per year through improved asset utilization, reliability, and operational consistency.

Caravel’s Operations Excellence Framework and Best Practices were fully implemented across internal sites and new acquisitions, creating a unified, performance-driven culture. The standardized OPEX system not only enhanced operational discipline and profitability but also significantly increased enterprise value—enabling the Private Equity owner to achieve a 3–4X return on EBITDA impact at exit.