A high-tech manufacturer of custom-integrated solar solutions was transitioning from a R&D-driven organization to full-scale industrial production. This transformation required more than just scaling operations. It demanded smarter systems, better collaboration. And a digital backbone that could handle complex, made-to-order manufacturing. PDM partnered with the company to guide this transition, supporting both industrialization and digitalization to reduce inefficiencies, improve quality, and significantly accelerate time-to-market.
The client is a leading European innovator in solar integration for buildings, vehicles, and infrastructure. Operating in a fast-growing, customized manufacturing space, this company produces highly tailored photovoltaic modules. Each product varies in size, shape, and aesthetic requirements, which makes traditional scaling approaches ineffective. Achieving operational excellence required a tailored solution across technology, systems, and people.
challenges
The company worked entirely on a make-to-order basis. While this allowed maximum customer flexibility, it included major production challenges: high complexity, varied product specifications, and a lack of standardization. Additionally, the factory still relied on paper-based workflows. Which led to quality issues, inefficiencies, and missed scaling opportunities. A system was needed to connect data, workflows, and people in real time.
PDM'S APPROACH
PDM supported the company in two critical areas: industrialization and digitalization.
- Supplier selection: PDM first assisted in selecting machine suppliers capable of handling the required customization. Proposals were critically reviewed, ensuring that final decisions were based on both technical capability and production flexibility.
- Production flow & data mapping: Eight intensive workshops were facilitated with internal knowledge holders to define the ideal production flow and data requirements. These sessions focused on identifying key data for quality assurance and operator input, laying the foundation for automation and traceability.
- MES selection and implementation: By guiding the tender process for a Manufacturing Execution System (MES), PDM ensured the system could support a high degree of flexibility. The company selected 24Flow as their MES partner. PDM acted as project coordinator by bridging teams, managing implementation, and ensuring a smooth rollout. The MES allowed for real-time visibility across the entire factory while eliminating paper-based processes.
- Change enablement: Throughout the program, PDM worked to align leadership, shop floor teams, and suppliers. This collaborative approach ensured buy-in at every level and helped embed continuous improvement practices from the start.
results & impact
The results of the program were both measurable and transformational:
- 50% faster MES implementation compared to the industry standard
- Fully paperless production environment, improving transparency and accessibility
- Faster time-to-market, enabling the company to scale up production more rapidly
- Increased productivity through streamlined data flows and reduced manual work
- Higher team engagement, with operators empowered by more structured workflows
- Improved onboarding, enabling new team members to learn the process faster
These outcomes were achieved despite additional challenges, including a full relocation of the production facility during the MES implementation phase. PDM’s structure and pace helped keep the project on track.
“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.”
This case highlights the operational complexity of transitioning from R&D to full production. This included real-world challenges: fragmented data, delayed decision-making, and manual workarounds. PDM helped resolve these issues by connecting people, processes, and systems in a tailored and practical way.
conclusion
With PDM’s support, the company cut MES implementation time in half, streamlined production, and built the digital foundation necessary to scale. The initiative did more than improve operations; it accelerated innovation and empowered teams to own the next phase of growth.
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