The client for the interim mandate was the HKO Heat Protection Group. The insulation and textile technology company operates plants in Oberhausen, Leinefelde, Beuren, France, the USA and China. The interim manager was engaged for the second time since 2016 to develop a logistics concept for an expansion of production capacities at the sites in Thuringia.
The particular challenge of this project was its complexity. On the one hand, a completely new logistics center was being built, and on the other, various adjustments to the logistics processes and storage capacities at the locations had to be developed and implemented. In addition, the shipping team had to be reorganized and restructured.
Interim solutions developed until the construction of a logistics centre
The plant in Beuren produces thermal insulation in rolls. On the one hand, this is delivered to customers as unmixed goods. On the other hand, the rolled goods are sent to the plant in Leinefelde, 5 km away, as primary material. Products for the automotive industry are manufactured there in the form of 2D punched parts and 3D molded parts for insulating manifolds, catalytic converters, diesel particulate filters or turbocharger casings as well as heat shields for exhaust systems. Both plants work in three shifts. The car manufacturers call off the products - the company delivers just in time.
After a third production line went into operation at the Beuren plant to increase capacity by 35 percent, the previous logistics capacities were no longer sufficient. The interim manager developed a comprehensive plan for a new logistics concept, which included the construction of a new logistics center on a greenfield site. The interim manager developed efficient and cost-effective interim solutions for the company's logistics until the new building is completed (expected in 2021).
Outsourcing to external warehouses reduces costs by one million euros
The interim solutions included optimizing, reorganizing and expanding existing warehouses. The interim manager also initiated the acquisition of suitable new shelving systems. By outsourcing single-variety goods to an external warehouse at a local forwarding partner, it was possible to avoid renting a 6800 m² warehouse. This enabled the interim manager to reduce storage costs by one million euros in three years. The agreement with the forwarding partner stipulates that the space to be made available is automatically adjusted to HKO's order situation - with invoicing per half month based on the quantity of pallets actually stored.
Coaching for modern and efficient logistics planning
The interim manager was not only involved in planning, negotiating and implementing the interim solutions. In an ongoing coaching session, he trained the employees in the shipping department in modern and efficient logistics planning.
New interim mandate in prospect
The interim manager implemented all measures in close coordination with the management, production and sales as well as plant management. The results were convincing. The interim manager was offered the prospect of a new mandate for 2021 to plan a new production plant with a logistics center.
