Initial situation:
- German Tier 2 supplier taken over by Polish investor following insolvency.
- Over 70% of production for Tier 1, continuous supply required.
- Complete relocation of four plants during ongoing production.
- Necessity: safety stocks, know-how transfer, personnel planning.
Our approach:
- A key supplier can no longer deliver - production & OEM supply are at risk.
- Pre-production and safety stock build-up planned and implemented.
- 630 tools, 65 injection molding machines, 2 paint shops, 26 assembly lines dismantled, relocated and put into operation in Poland.
- Detailed recruiting and training program for Polish teams.
- Control of sampling, PPAP and series releases, parallel phase-out in Germany.
Results:
- Complete relocation in 1.5 years under load, without supply interruptions.
- Successful ramp-up and integration at the new location.
- German plant closures legally concluded.
Conclusion
From crisis to stability – complete relocation and start-up successfully mastered.
