Case Studies
Selected projects from international assignments in procurement, production, restructuring and site establishment.
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Our Case Studies
The projects presented encompass international leadership responsibility for up to 220 employees, purchasing volumes exceeding €100 million, as well as turnaround, greenfield, industrialisation and transformation projects across Europe, Asia and the Americas.
General Management of an Automotive Cable Plant – Turnaround to Double-Digit Profitability
Initial Situation
Assumed general management of an automotive cable plant in a difficult position. A negative operating result, outdated structures, high failure costs and inadequate delivery reliability jeopardised OEM approvals and market position. Full P&L responsibility for approximately €80 million in revenue.
Measures
Building a high-performing management team, restructuring production, introducing lean methods, developing new product lines, optimising cost structures and quality systems to automotive standard.
Result
Nine years of successful general management, double-digit profit in 2022, failure costs −16%, OTD raised to 95% (+18%), DAkkS laboratory accreditation.
Plant Establishment in China – €20 Million Greenfield with OEM Approval
Initial SituationGreenfield project in China with an investment volume of €20 million. No existing team, no infrastructure, significant time pressure from OEM requirements.
MeasuresSite selection, machinery selection and procurement, building a high-performing local team, securing OEM approval and ISO 16949 certification.
ResultProduction start within 10 months, budget held at €20 million, successful OEM approval and ISO 16949 certification.
Supplier Development Europe–Asia – €100 Million Purchasing Volume
Initial SituationPurchasing volume exceeding €100 million with high dependence on European high-cost countries. Lack of market knowledge and supplier base in Asian markets, particularly China.
MeasuresPersonal market visits and supplier audits in Asia, building an international supplier network, developing a relocation strategy from high-cost to low-cost countries, cross-cultural negotiation and long-term partnership development.
ResultAnnual savings of 7–10%, sustainable global supplier partnerships, effective risk management through diversification.
Lean Transformation in a Production Plant with 220 Employees
Initial SituationProduction volume €170 million, 220 employees. Optimisation potential in processes, equipment efficiency, set-up times and delivery performance.
MeasuresIntroduction of 5S and lean, push-pull principles, set-up time optimisation, equipment efficiency improvement, batch-size optimisation and design-to-cost projects for product cost optimisation.
ResultProduct costs −15–20%, OTD improvement to 92% (+20%), reduction of time-to-market from 6–8 to 4–6 months.
Industrialisation of the World's First Corrugated Aluminium Cable
Initial SituationDevelopment and industrialisation of an entirely new cable type with no comparable reference worldwide. Highest technical demands on material, manufacturing processes and quality assurance.
MeasuresIndustrialisation and series launch of the world’s first corrugated aluminium cable, development of new manufacturing processes, securing series readiness and international rollout to several production sites.
ResultSuccessful worldwide market launch, reduction of time-to-market for transfer projects from 4 to 2 months.
Technology & Site Transfer
Initial SituationIn the course of integrating a German production site into a French corporate group, technology, know-how and production responsibility were transferred to France – including demanding product development.
MeasuresTransfer planning with cost planning, layout and machinery relocation, intensive training and qualification of the French workforce, ensuring production continuity throughout the relocation.
ResultOn-schedule project completion, variable margin 30–35%, full technology transfer with no production interruption.
Turnaround Consulting, Cable Plant South Africa
Initial SituationCable plant in economic distress with liquidity shortfalls, delivery problems, quality challenges and substantial restructuring needs.
MeasuresAnalysis of operational capability, stabilisation of critical processes, supporting management with restructuring measures, improving production, quality and delivery processes.
ResultCreated transparency, identified fields of action, supported operational stabilisation and developed sound decision-making foundations for owners and investors.
Leading a Global Production Network with Four International Sites
Initial SituationOverall operational responsibility for cable plants across four continents – simultaneously, with different cultures, markets and regulatory requirements.
MeasuresBuilding local leadership teams, harmonising processes and production standards across all sites, cross-site optimisation of machinery and equipment, cross-cultural leadership and transformation of the production networks.
ResultSuccessful operational leadership and development of four international production sites, harmonised production standards, significant efficiency gains, reduction of time-to-market for transfer projects from 4 to 2 months.
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