Situation

The move to the new site with the newly constructed production building did not go as expected. As soon as they moved in, quality and delivery problems became more frequent. This led to a major uproar and finally discussions among customers.

Challenges

Initially, the move to the new production building went smoothly. The systems were put back into operation and produced as before. The old processes were therefore retained. But that was a mistake. Delivery bottlenecks soon became more frequent due to a lack of materials and components. Quality defects were only recognized late in the production process. This not only disrupted internal processes, but customers also became restless and began to question the delivery quality.

In the end, entire production lines could no longer be started up because the material was missing. The plant manager was no longer able to cope with the situation and left the company without further ado. Fortunately, one of our interim managers was able to step in immediately as COO. He quickly brought the company back into balance. By analyzing processes and systems, defining measures and ensuring stability. The analysis showed that production output had not been achieved:

• The test benches were not fully assembled
• Employees were working inadequately
• Inventory was not being carried out. This led to stock discrepancies, which in turn led to production downtime
• Tools and entire workstations were missing in production

Action

The interim manager arranged for extra hours over three months. He simplified processes and trained employees on quality issues. He also introduced an incoming goods inspection. He supported the development of a new QM system and helped to evaluate a new COO.

Results

The interim manager was able to gain the trust of employees and customers within a short space of time. He credibly conveyed that the delivery problems could be resolved quickly. And he proved it. Production output was soon increased by 30% with his help. The CEO was able to return to his duties and no longer had to worry about production. He thus brought the desired stability back to the company within a few months.