References

Production relocation and plant closure

Challenge: High energy and labor costs in Germany combined with high margin pressure required significant cost reductions in order to avoid losing business.

Solution strategy: Relocation of production from Germany to Eastern and Western Europe while maintaining ongoing deliveries.

Development of the general plan and coordination with the executive board and supervisory bodies.
Qualification of target plants.
Assumption of overall responsibility as CRO during the restructuring phase.

Closure of the plant in Germany

Social plan, job placement for employees.
Plant closure, sale of property, and winding up with authorities.

Results:

Sustainable customer loyalty and improved customer satisfaction.
Restoration of sustainable long-term profitability.

Turnaround: Restructuring of a mechanical engineering and automotive supplier group

Challenge: Turnaround and strategic realignment of a group of companies with locations in Germany, Poland, the USA, and China.

Solution strategy: Development of 65 activities for cost reduction, portfolio realignment, and business activation.

Coordination with shareholders, customers, and bank pool.

Execution as CRO.

Leadership during the restructuring phase.
Controlling and follow-up of measures
Closure of a plant
Relocation of production
Customer portfolio expansion

Results:

Increase of profitability by € 30 m; restoration of adequate profitability
28% staff reduction
Regained confidence by the financing banks

Business activation and structural setup for global supply chain

Challenge: Business activation and cost-effective market entry on three continents by way of utilizing international logistics structures and innovative production concepts.

Solution strategy: Applying CKD strategy (completely knocked down) strategy to household appliances.

Development of the overall concept for production, logistics, customs clearance, local regulations, assembly, quality assurance, and marketing.

Execution as COO after approval by parent company

Process development and introduction for production, packaging, and logistics handling
Assembly plant planning for target countries
Overall process ramp-up and verification with handover audit to the customer's management

Results:

Successful market launch in 5 countries
Efficient use of existing overcapacity in Brazil and utilization of customs regulations for local value creation by assembly jobs in the target countries

Optimized maintenance and repair facility network for buses and trains in public transport

Challenge: Need to increase the level of service and reduce the reserve vehicle ratio while optimizing the total costs for local buses and trains.

Solution strategy:

Analysis of work organization, structures, loss times (reserve ratios), supply conditions, and their impact on total costs.
Definition of maintenance strategy with a focus on
- Reorganizing the facility network (e.g., specialization)
- Setting up structures to carry out simple jobs in terminal stations
- Increased use of external service providers
- Standard facility organization (workflow, supply, damage pre-reporting, equipment, qualifications)

Results:

Cost reduction of €12 million p.a.
Reduction of unplanned downtime > 30% and thus reduction of the reserve vehicle ratio

References

Customers who relied on us

Project examples

Production relocation and plant closure

Turnaround: Restructuring of a mechanical engineering and automotive supplier group

Business activation and structural setup for global supply chain

Optimized maintenance and repair facility network for buses and trains in public transport

Contact

TEAM ALPHA Consultants GmbH