Challenge
A pharmaceutical manufacturer planned to expand capacity with a new production facility. Development, engineering, and commissioning had to be completed on time and in full compliance with GMP standards.
Success
Supported development and engineering of the facility
Guided commissioning and ramp-up
Implemented a KPI dashboard for process stability
Ensured regulatory compliance (GMP, Data Integrity)
Impact
Smooth ramp-up of the facility
GMP-compliant processes from day one
Stable quality and supply capability
Annual savings of €2–3 million
Challenge
A manufacturer in the energy sector faced severe issues with a critical supplier component that could not be sourced elsewhere. Quality defects and delivery delays threatened projects and created significant cost risks.
Success
Reviewed and optimized the supplier’s manufacturing process
Conducted root-cause analysis with KPI-based quality evaluation
Stabilized production parameters through continuous monitoring
Introduced process controls to secure supply capability
Impact
Improved quality of critical components
On-time deliveries restored
Project stability ensured
Annual benefits of €10–15 million
Challenge
A food manufacturer struggled with long setup and cleaning times in extrusion, fluctuating quality, and high scrap rates.
Success
Shortened setup and cleaning times through standardized procedures
Stabilized quality parameters with data tracking
Reduced scrap via data-driven root-cause analysis
Adjusted and optimized recipes based on line data
Impact
20–25% reduction in setup and cleaning times
3–4% scrap reduction
More stable quality with fewer fluctuations
Increased output
Annual savings of €3–5 million
Challenge
A consumer goods manufacturer transitioned from an existing production process to a new technology. The international technology transfer between the US and Germany required trial execution, data integrity, and quality stability across high product variability.
Success
Coordinated activities between international sites
Conducted and evaluated trials to ensure process stability
Built a reliable data foundation
Introduced standardized KPIs for quality and output
Impact
Successful technology transfer between the US and Germany
Stable implementation of the new technology
Increased output
Annual savings of €2–3 million
Challenge
Following an acquisition, multiple international plants had to be integrated and processes standardized. Divergent standards resulted in high material costs and long setup times.
Success
Harmonized processes across plants
Centralized data and KPI alignment between sites
Implemented best practices
Introduced monitoring for improved production planning
Impact
10–15% cost reduction
30% reduction in setup times
Increased output
Annual savings of more than €10 million