Organizational transformationin medical technology

The problem was clear. The existing structure was not designed for this level of growth. Assembly was organized in a manufacturing style island production, characterized by bottlenecks, high variability and limited capacities. The team was highly motivated, but the system was working against them. It was obvious that growth could not be managed this way.

Together with the company, I started a multi year, holistic transformation. The first step was creating transparency.

We took a deep dive into the data using an ABC XYZ analysis to understand the product landscape, refine forecasts and gain clarity about real customer demand.

Based on these insights, we made a bold decision to fundamentally change the system. The island production was transformed into a takt capable, flowing line structure that was structured, scalable and designed for growth.

To make this transformation work, we systematically created the necessary foundations:

• setup workshops to reduce changeover times and increase flexibility
• line balancing workshops to establish stable and predictable processes
• employee training to make Lean principles tangible and applicable
• intensive change management to involve everyone and use resistance constructively
• introduction of a new team leader level that was clearly defined, empowered and trained for leadership
• shopfloor management as a daily steering and control routine
• a KPI system that provides orientation, supports decision making and makes success visible

These changes went deep. Into processes, structures and above all into the company culture. And that is exactly where real transformation happens.

After several years of consistent development, the company achieved what initially seemed almost impossible:

• production output increased significantly
• the organization worked in a more structured, stable and transparent way
• employees were proud to be part of the transformation
• the company became more resilient, flexible and future ready

And the highlight:

For this exceptional achievement, the company was awarded the prestigious Factory of the Year prize in the category Best Transformation.

Because it shows what becomes possible when a company has the courage to truly reinvent itself. Structured, holistic and with people at the center.

Transformation is not a project. It is a journey. And when it is guided well, growth can suddenly become achievable.