Case Study

Operational Transformation for Sustainable Success

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How a High-Tech Company Significantly Increased Production Output and Competitiveness

A medium-sized high-tech company overcame key challenges by implementing operational transformation, cost reduction, and management structure change. Long-term success was achieved by increasing OTIF to 95%, increasing production output by 33%, and improving competitiveness.

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Company Details

Medium-sized high-tech company, part of a global group, specialising in high-precision motion and control systems for semiconductor production
Sector: Semiconductor and high tech
Main site in Germany

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Situation and Challenge

Challenged by inefficient processes and high proportion of temporary workers (>20%)
Low delivery reliability (On-Time In-Full, OTIF) of less than 65% and delivery bottlenecks jeopardise key customer relationships
Internal inefficiencies, high labour costs and a disrupted supply chain threaten long-term competitiveness

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Objective and Tasks

Increase production and significantly improve OTIF
Reduce labor costs by 10% and establish a stable management structure to ensure operational stability

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Measures and Procedures

Introduction of a new top-down management structure and reduction of micromanagement
Targeted reduction of labor costs by reducing the proportion of temporary workers and optimizing performance
Process standardization and technical improvements to increase efficiency

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Results and Successes

Improved OTIF rate to over 95% and increased production by 33% in 6 months
Successful implementation of an EBITDA recovery program in operations
Efficiency improvements through workforce adjustments and process standardization sustainably strengthened competitive position