From growing pains to performance gains
A leading European textile manufacturer experienced sustained growth, producing over a million square meters of assembled textile annually across multiple sites. However, as operations scaled, the company began to face challenges delivering on its core promises of quality, speed and service. Performance targets were slipping, customer satisfaction was impacted and operational complexity was on the rise.
Ambition: Next-gen leadership, Next-level operations
With new leadership, the company aimed to future-proof operations and reinforce core values. To support this transition and meet customer expectations, the entire operational value chain - from order intake to delivery - was assessed, and a roadmap for Operational Excellence was defined. The focus was on improving efficiency, planning and shopfloor discipline through Lean techniques and structured scheduling.
How we helped: Enhancing efficiency and quality using Lean Six Sigma brought lasting operational improvements
An in-depth operational audit using Lean Six Sigma techniques had identified four key improvement levers: shopfloor layout, planning tools, roles & responsibilities, and quality culture. Targeted changes included redesigning the production layout to enable lean material flows. Demand-driven planning concepts and visual BI reports were introduced. Responsibilities were clarified and work instructions were refined. Training materials were developed to support capability building. A cultural transformation was initiated, focusing on workplace order (shopfloor, 5S), quality standards and leadership engagement. This was reinforced through daily routines and transparent communication (PDCA).
Results: Seamless implementation and sustained Operational Excellence
Within four weeks, the new production layout was implemented without disruption, supported by detailed transition planning. Visual planning tools improved control and transparency, enabling more predictable operations. Work instructions and training strengthened onboarding and role clarity, while leadership involvement reinforced accountability and continuous improvement. Cultural change is now underway, ensuring sustained operational excellence through a continuous improvement (CI) culture (PDCA, lean six sigma). The stabilized production environment resulted in an increase in product quality, ensuring that the company could maintain its leadership position in the textile industry.
Looking to strengthen your operations and prepare your business for future growth? Contact us today to learn how we can help you.
