A large European manufacturing group set out to improve operational efficiency across its international production network. Facing variability in performance across sites, the company partnered with PDM to roll out a hands-on LEAN-based OEE (Overall Equipment Effectiveness) improvement program. The initiative resulted in measurable gains in productivity, throughput, and engagement. All within one year.
The client is a leading European manufacturer of heating and comfort solutions with multiple production facilities across the continent. Operating in a competitive, cost-sensitive market, this manufacturer relies on high operational efficiency and timely deliveries. Each factory has its own legacy processes and performance challenges, creating the need for a harmonized approach to improvement across locations.
Four of the client’s production plants in Europe had inconsistent OEE levels, frequent changeovers, and missed productivity targets. Manual practices, limited visibility, and inconsistent stakeholder involvement hindered sustainable performance. The challenge was to develop a program that delivered local results while building a consistent LEAN foundation across all sites.
PDM was brought in as a hands-on partner to provide LEAN expertise, enable internal ownership and sustainable change. Rather than applying a top-down model, PDM worked side-by-side with teams on the shop floor, guiding them through the tools, data, and behaviors that make continuous improvement stick. The program included:
The program produced strong quantitative and qualitative outcomes:
The structured yet flexible approach allowed each site to benefit from centralized tools while applying them to local conditions. At one plant a line was shut down due to improved capacity on others, resulting in direct labor savings. In another plant, small-group activities led to a 10% rise in productivity. And at the third plant, despite already low labor costs, OEE and shop-floor engagement led to productivity gains over 25% and improved morale.
“The program brought structure in our improvement routines and introduced a clear and visual way of working with OEE, resulting in higher engagement and measurable improvement on the production lines.”
Operations Director
This case shows how LEAN programs can expose hard truths: fragmented routines, resistance to change, and underused shopfloor knowledge. PDM tackled these issues by building trust, clarifying KPIs, and facilitating structured problem-solving sessions across all plants. This highlights that the success of LEAN isn’t just in tools. It’s in ownership, persistence, and culture change.
PDM’s structured rollout helped this international manufacturer measurably improve performance across four sites within one year, while building internal capability and cross-site alignment. The initiative didn’t just reduce waste; it built a culture of continuous improvement.
The program laid the foundation for future LEAN projects and internal LEAN agent training. Based on its success, similar approaches are now being considered at additional sites across the group. The initiative set the groundwork for forthcoming LEAN endeavors and the training of in-house LEAN agents. Given its accomplishments, comparable strategies are currently under review for implementation at other locations within the organization.
Curious how we could create results like this in your production environment?
Contact PDM to explore how our LEAN programs can boost your OEE, streamline changeovers, and empower your teams.
Or ready to take the lead on programs like this yourself?
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