1. Rapid Operational Assessment

• Conduct a structured plant audit (typically 1–2 weeks) to:

  • Identify bottlenecks, inefficiencies, and hidden capacity

  • Evaluate production flow, staffing, material handling, and KPIs

  • Assess cultural and communication gaps between German and U.S. teams

  • Interview key personnel to understand root causes of performance issues
     

2. Customized Recovery Roadmap

• Deliver a clear action plan with:

  • Short-term quick wins

  • Medium- and long-term improvements

  • Recommended tools (LEAN, TOC, Six Sigma, TPM, etc.) tailored to the situation

• Prioritize actions that stabilize production and improve delivery and quality metrics.
   

3. Hands-On Implementation Support

• Roll up sleeves to help execute the plan, including:

  • Implementing LEAN production cells and visual management

  • Applying Theory of Constraints to maximize throughput and exploit key bottlenecks

  • Introducing flow, pull systems, or standard work as needed

  • Realigning staffing, roles, and leadership structure if necessary

• Support change management and team buy-in from the shop floor to management.

 

4. Team Coaching & Culture Reset

• Bridge cross-cultural disconnects (e.g., differing expectations around authority, feedback, autonomy).

• Coach managers and supervisors in effective leadership, problem-solving, and continuous improvement habits.

• Improve communication between U.S. teams and German headquarters.
   

5. Performance Monitoring & Follow-Through

• Establish simple, visual KPIs and reporting dashboards.

• Schedule regular follow-ups to ensure improvements are sustained.

• Optionally provide temporary leadership (e.g., interim operations manager) during critical phases.
   

Common Issues Resolved

• Chronic delivery delays or quality problems

• Poor workforce engagement or high turnover

• Underutilized equipment or production lines

• Unclear leadership roles or communication breakdowns

• Misalignment between German HQ expectations and U.S. execution
   

Client Benefits

• Stop the bleeding and regain operational control quickly

• Restore profitability and customer satisfaction

• Empower the U.S. team with effective tools and leadership

• Build a stronger, scalable foundation for future growth

• Strengthen trust between the German HQ and the U.S. subsidiary