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-22

%

Operational cost

18

%

Output volume

-30

%

Cycle time

95

%

To full rollout

01 The Challenge

Rising costs and fragmented processes were limiting growth

The client operated three production sites with inconsistent workflows, redundant manual steps and limited visibility into performance. Cycle times varied widely between plants, and rising operational costs were beginning to erode margins. Leadership needed a clear, data-backed path to standardize operations without disrupting day-to-day production.

  • Three sites running inconsistent, non-standardized workflows
  • Redundant manual steps with limited performance visibility
  • Rising operational costs eroding margins year over year
02 Our Approach

A structured, phased redesign built on real data

We began with a detailed value-stream analysis across all sites, then designed a standardized target operating model and rolled it out in controlled phases to minimize disruption.

Value-stream analysis

We designed a standardized model with shared KPIs, roles and routines tailored to the client’s reality.

Target operating model

We designed a standardized model with shared KPIs, roles and routines tailored to the client’s reality.

Phased rollout

We deployed in controlled phases with on-site coaching to embed change without disrupting production.

03 The Solution

A standardized operating model delivering measurable results

The new model unified workflows across all three sites, introduced shared performance dashboards and embedded continuous-improvement routines. Within nine months the client saw consistent, repeatable gains — with operational costs down and output up across the board.

YAVI Lucerne gave us a clear, pragmatic plan and stayed with us through execution. The results speak for themselves — and they're sustainable.
Markus Keller
Markus Keller
COO, Manufacturing Client
Project Facts
Industry
Manufacturing
Company size
1,200+ employees
Engagement
9 months
Sites involved
3 production plants
Region
DACH
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