Initial situation:
- Tier-2 injection molding supplier in southern Germany became economically unsustainable after insolvency and was acquired by a Polish investor.
- Over 70% of production volume supplied to major Tier-1, requiring uninterrupted supply.
- Full relocation of four plants necessary, under running production, with complex tool, machine, and process transfers.
- Urgent need for safety stock buildup, personnel transfer, and knowledge migration to ensure continuity.
Our approach:
- Established a dedicated task force for full project management, including weekly customer alignment meetings.
- Planned and executed pre-production runs and safety stock builds.
- Dismantled, transferred, and commissioned 630 molds, 65 injection machines, 2 paint lines, and 26 assembly lines in Poland.
- Developed a detailed recruitment and training program in Poland, ensuring effective knowledge transfer from German teams.
- Managed PPAP, sampling, and serial production approvals to secure on-time industrial ramp-up; managed parallel phase-out and site closures in Germany.
Results:
- Completed full plant relocation within 1.5 years — under full load, without supply disruptions.
- Successful ramp-up and integration at the Polish site.
- Completed German site closures in compliance with labor and legal agreements.
Conclusion:
Complex multi-plant relocation executed seamlessly — securing supply chains, transferring know-how, and stabilizing the company under extreme conditions.
