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Scaling a High-Growth Company while Ensuring Quality, Time and Costs

Interim Mandate Objective as COO ad interim
 

Transformation of operational structures to manage exponential growth while simultaneously stabilizing quality and processes in a VC-funded environment.

Company from the Electronics Sector
 
Operator of a Virtual Power Plant and manufacturer of solar battery storage systems for private and commercial uses, with approx. 450 employees and approx. €300 million revenue
 
Identified Intervention Areas

  • Massive discrepancy between demand and production capacity

  • Extremely short product lifecycles (90% of revenue from products <3 months)

  • Overloaded change management

  • Significant quality issues due to lack of product maturity

  • Insufficient product documentation

  • Overloaded service hotline

  • High obsolescence in material inventories

  • Lack of process stability due to rapid product changes

  • Inefficient manufacturing structures

  • Lack of data transparency and analysis capacity
     

Implemented Measures

  • Implementation of Kanban control loops for production smoothing

  • Development of dynamic forecasting for dynamic on-stock planning

  • Establishment of interdisciplinary Kaizen teams

  • Improvement of data quality through analytics and BI

  • Introduction of daily dashboards

  • Optimization of interface management

  • Reorganization of manufacturing structure

  • Professionalization of product in- and out-phasing in close coordination with R&D and product marketing

  • Implementation of strategic personnel adjustments

  • Restructuring of service desk organization

  • Conducting leadership development
     

Results

  • Increase in production output by a factor of 5

  • Successful servicing of high market demand

  • Establishment of scalable parallel production lines

  • Significant reduction of material inventories

  • Implementation of effective frozen zones

  • Improved product and process quality

  • Optimized service level structures

  • Professionalized management level

  • Stabilized production processes

  • Improved data transparency
     

Applied Competencies

  • Experience in scaling fast-growing manufacturing companies

  • Expertise in lean management and Kanban systems

  • Competence in building analytics and BI structures

  • Know-how in optimizing manufacturing processes

  • Experience with agile development methods

  • Expertise in change management under high pressure

  • Ability for rapid process optimization

  • Competence in leadership development

  • Experience in dealing with VC-funded companies

  • Expertise in implementing quality systems

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