In 2020, a European ladder manufacturer decided to consolidate its global production in Europe in order to save costs and simplify logistics. To do this, a large production facility, a 180-metre-long aluminum extrusion line, had to be relocated from Vietnam to Hungary and upgraded with additional tools. The current interim manager acted as project manager for the relocation and upgrade of the extrusion line.
Project plan developed and specifications for the relocation drawn up
In the first step, the interim manager developed a detailed plan for the 12-month project. At the start of the project in July 2020, he immediately began contacting relocation companies in Vietnam and Germany for the complex production relocation. He drew up a specification sheet in which the scope was described in detail. The specifications also included acceptance criteria (OEE, machine availability, output, set-up times, etc.) for the recommissioning of the extrusion line in Hungary. Due to travel restrictions (Corona), the German companies had to refrain from submitting a binding offer. The interim manager therefore commissioned a company from Vietnam.
Preparing to expand production by 196 new products
One of the major challenges was to maintain the client's ability to deliver during the transport phase. In order to ensure the ability to deliver, the interim manager had the requirements for the 8-month transport and reconstruction phase pre-produced in consultation with the management.
With the reconstruction in Hungary, the production portfolio was also to be expanded by 196 products. The interim manager had the necessary tools procured in Vietnam and fully validated on site before the extrusion line was dismantled. In order to ensure that the start-up of the line in Hungary went smoothly, he had the line comprehensively serviced before it was dismantled. In order to be well prepared for all eventualities, he also had a spare parts package procured.
Successful transportation despite a strained supply chain
The global supply chain was very strained due to the coronavirus pandemic and the procurement of containers was extremely difficult. The transportation of the system therefore proved to be a bottleneck for the progress of the project. By tracking the 52 transport containers on a daily basis, the interim manager was able to adapt the planning for the reconstruction to the progress of the transport at all times.
Even before the first containers arrived in Hungary, he sent a team of experts from Vietnam (plant operators, quality, maintenance and technologists) and employees from the manufacturer of the extrusion line to Hungary to check the infrastructure measures in Hungary and jointly support the construction.
In this way, the production site in Hungary was well prepared for the reconstruction. For the series acceptance of the extrusion line in Hungary, the interim manager first had the products defined in the specifications manufactured and validated. He then developed a plan that defined the sequence of further tool validations.
New site starts improved production with a short delay
The commitment of the current interim manager played a key role in ensuring that series production at the new site in Hungary could start with only a slight delay. The ability to deliver was ensured at all times. The company achieved all the objectives of the relocation. In addition, output was increased and the reject rate reduced. The transfer of know-how from Vietnam to Hungary was also a great success. The company has now bundled its capacities in Europe, can produce more economically and has shorter transport routes to the European production plants.
