Case study: Project management

Our customer, a leading Tier 1 supplier in the automotive industry, was facing a major challenge. A new product was to be industrialised for an OEM that was more complex than anything the company had ever developed before. The requirements were high: a new production site had to be set up in Poland and the expansion of the existing plant in China was planned. However, the project team, which was based at various locations around the world in China, Singapore, Japan, Poland and Germany, had limited experience of industrialising such a sophisticated product.

Our role as consultants was to support the existing project management team and ensure that the project was implemented successfully. This included creating an effective reporting structure, categorising activities into work packages and promoting knowledge sharing between the teams in the different countries.

One of the major challenges was to fulfil the customer's logistical requirements during the prototype construction phases. These sample components had to be delivered to the OEM's pre-series location during industrialisation. The accounting processing was carried out via a location in Germany. The quality of the products had to meet the customer's requirements and there could be no delays in delivery.

To overcome these challenges, we implemented various solutions. One important approach was to improve the logistical processes for shipping sample parts. By planning efficiently, adhering to the customer's packing instructions and coordinating deliveries, we were able to ensure that the sample components arrived on time and in perfect condition. This included working with freight forwarders and using efficient transport routes to minimise delivery delays.

Another challenge was to evaluate and optimise the costs of logistics from the factory to the customer. By analysing the logistics processes in detail, we were able to identify and implement potential cost savings. This included the optimisation of transport routes, the use of freight rate negotiations and the minimisation of storage costs.

Despite some challenges, such as the time difference between Europe and Asia and the customer's frequent deadlines, we were able to successfully manage the logistical requirements during industrialisation. The close cooperation between the teams in China, Poland and other locations helped to minimise delivery delays and guarantee the quality of the products.

In addition to the logistical challenges, further measures were taken during the project to ensure success. These included the evaluation of sustainability issues in the development process, such as increasing the proportion of recycled aluminium, and the introduction of processes for successful just-in-time delivery.

Overall, the successful collaboration on the industrialisation of this complex product was a good example of our company's ability to master the demanding challenges in the automotive industry. Through effective planning, coordination and optimisation of the logistics processes, we were not only able to meet the customer's expectations, but also ensure long-term success for our company.