Transformation at a Manufacturer of Solar Inverters

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Sustainable Process Improvement and Cost Optimization through Production Relocation

An EMS service provider and manufacturer of solar inverters secures output through stepwise production relocation and reduces costs. Execution without delivery interruption boosts efficiency and embeds lasting improvements in project management and production strategy.

Company

EMS provider and manufacturer of solar inverters with in‑house development
Sites in Germany and Bulgaria with approx. 1,100 employees and €180m in revenue

Challenge

Supply of electronic components severely constrained due to external crises; risk of production interruptions and revenue loss
New product with significant SOP delay

Goals

Safeguard production capability and revenue delivery for major customers (€54m)
Relocate the main solar product to optimize costs and increase output volumes
Sustainably improve project management and the company-wide production strategy

Measures

Established an escalation structure spanning procurement and sales; daily coordination with suppliers, sales, and procurement
Phased, synchronized transfer of the main product to Bulgaria; alignment of production equipment to prevent production stoppages
Interim takeover of site leadership and targeted training of project managers to clarify roles and enable efficient execution

Results

Production capability secured in the short term, enabling €54m in revenue; €21m in additional costs successfully passed on to customers
Relocation executed without delivery interruptions, increasing output and achieving €0.75m in production cost savings within three months
Expansion of the Bulgarian site by +230 employees; significant improvement in collaboration and established activity control for Operations