We successfully relocated an automotive supplier's precious wood trim production from Germany to Romania in just six months — six months faster than originally planned. I significantly accelerated the process, which was originally scheduled to take over a year, thanks to my innovative approach, saving the company millions in costs.
Instead of relocating all work steps one after the other, we started with processes that were easily transferable, such as those in the development department. This was followed by injection moulding machines, paint shops, and other production steps. The most complex systems, such as presses weighing several tons, were relocated last.
Thanks to the non-linear relocation, the risk of delays was significantly reduced, while efficiency was increased at the same time.
During the relocation process, materials were transported several times between sites in Germany and Romania. Using existing transport links enabled us to avoid additional costs in the six-figure range.
Parts production was already operating profitably during the ongoing relocation. This meant that the project was faster and more economically successful than planned.
The successful relocation of trim part production is an exemplary pilot project for the entire plant expansion to Romania. Thanks to this innovative method, the process time was halved, enabling the automotive company to save millions as well as valuable time.
By optimizing the building infrastructure and reducing floor space by 30%, investments of EUR 1.9 million were saved. Additionally, a new plant construction order was realised without additional investment.
An automotive supplier was sued in the USA. The supplier had been missing important documents. The lawsuit resulted in high costs. A structured analysis and and clear processes can create legal certainty and optimise inefficient workflows.
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