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Case Study

Interim operations turnaround at Romanian plant

230671-05

Stabilized processes and upgraded automotive site

An automotive supplier faced severe pressure from delivery delays, recurring quality issues and an overstretched workforce in his Romanian plant. An Interim Director Operations stabilized processes, cut stock variances significantly and returned the plant to sustainable profitability.

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Company​

  • Automotive supplier, part of a global group with dozens of locations worldwide 
  • Production site near Bucharest with well over 100 employees and mid single‑digit € million revenue
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Challenge​

  • Severe customer escalations due to delivery delays and logistics backlogs at the Romanian production site
  • Critical quality complaints with high scrap and sorting costs 
  • Overstretched, demotivated workforce and lack of standardized processes
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Goals​

  • Stabilize operations, secure key accounts, limit financial losses 
  • Restore delivery performance and significantly reduce complaints 
  • Prepare the plant to take over additional production lines
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Measures

  • Clarified roles and responsibilities, introduced daily shopfloor routines and KPI control 
  • Redesigned material flow, inventories and regular quality reviews 
  • Launched improvement program with 5S, TQM, TPM, SMED and layout optimization 
  • Planned and managed full factory relayout and facility upgrade, including tenders and permits
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Results​

  • Inventory discrepancies reduced to less than 1% of annual sales, production productivity increased by over 30 
  • Backlogs eliminated, customer escalations and sorting activities ended 
  • Site returned to profitability within 10 months and enabled for additional transferred lines