Set the pace for dramatic turnaround and revitalization of a $650M international industrial group that lost 30%–45% sales/volume from 2008 recession and world economic crisis. Defined and defended a bold plan of recovery and rebirth to the board and senior management, overcoming initial resistance with full approval and support.
Scope: 3360 Workforce / $650M Sales / Full P&L / 10 manufacturing sites throughout Spain, Portugal, Brazil, Mexico, Total area: 124,000mtr/2
Direct reported to : CEO Peguform Germany
Indirectly reported to: Board Peguform Germany
Direct reports: 10 Directors Central office Barcelona (Logistic, Finance, HR, Paint, Injection, Assembly, Marketing, Commercial, Engineering, IT), 10 plant managers
Client´s: VW Spain, VW Brazil, VW Portugal, VW Mexico, VW Germany, PSA Spain, PSA France, Mercedes Spain, Mercedes Germany, Audi Germany, Seat Spain, Renault-Nissan Spain, Fiat Brazil, Renault-Nissan Brazil, GM Brazil, BMW Brazil.
Industry Type: Plastic Exterior and Interior parts and assemblies, Exterior Fascias systems including Front end assemblies , trim and spoiler assemblies, Interior Door systems, central cockpit assemblies.
Technologies: Injection up to 4000 tons, Robotized paint lines, 2k injection process, Carbon fiber prototype and low production processes, weight reduction technologies, internal laboratory with complete crash test facility. (Brazil).
- Completed global cost reduction plan in 3 months—reduced headcount from 3360 to 1900, slashed inventory from 5 days to 2, renegotiated consignment contracts and supplier terms from 30 to 60 days.
- Closely monitored all plant operations enterprise-wide through an intranet-based scorecard with 10 KPIs for each function area.(weekly scorecard reviews with each plant team)
- Identified highest growth potential in Latin America and deployed to Brazil to lead design and build of lean Greenfield manufacturing sites in Brazil and Mexico; pre-trained operations teams for immediate start-up.
- Reversed negative EBIT by 400% to $12M (1.5% profit) in first year, even as sales dropped 30%.
- Leveraged increased production capacity provided by Greenfield facilities to ignite revenue growth from $60M (2009) to $90M (2011) and $150M (2013) as the economy picked up and demand returned.