Ramp-up of cleanroom-based wafer carrier production in new country location

Cleanroom production

rent-a-manager® Kapazität:

Mr.G. S.

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  • Customer:

    Confidential

  • Role:

    Interim Project Manager – Site Relocation

  • Location:

    Slovakia

  • Turnover:

  • Time frame:

    3 months

  • No. of employees:

    Approx. 120 at target site

About the Customer

A leading manufacturer of high-precision plastic components for cleanroom applications acquired a new business unit in wafer production. The company is known for its precision engineering, innovative technologies, and strict cleanroom standards.

Testimonial from Сustomer

“I’ve been tied up with other matters for a few days, but I want to take this opportunity to thank everyone involved. The series production started on time under challenging conditions. This professional execution laid the foundation to recover quickly and get our customers back on track. We’re on a good path.”

Situation (Challenge)

As part of this strategic project, the complete cleanroom production had to be relocated from the German plant to Slovakia within 3 months.

The project faced the following key challenges:

  • A new business in a new industry.
  • No support from operational functions like Purchasing, Logistics, and IT from Germany.
  • Employee absences due to insolvency.
  • Limited insight into the acquired business due to restrictions from the seller.

Solution (Achievement)

As Interim Project Manager, my main task was to relocate 100% of the production to Slovakia. The implemented measures included:

  • Dismantling and rebuilding the cleanroom and the cleaning system.
  • Testing, selecting, and commissioning a new filter system.
  • Building the infrastructure at the new location.
  • Digitalizing process data and adapting the ERP system.
  • Knowledge transfer, documentation, and training for the new employees in Slovakia (cleanroom, manufacturing, packaging).
  • Planning and managing 20 workstreams.
  • Smooth transfer of machines and tools.
  • Process optimization at the new site.

Results

The project was successfully completed, leading to the following outcomes:

  • On-schedule commissioning: The planned production was 100% relocated and commissioned within the timeframe.
  • Economic success: A +7% increase in profit margin through optimized processes and independent production.
  • Autonomy: The plant in Slovakia can now continue production without support from Germany.
  • Quality assurance: Successful customer audits and qualification of new suppliers were achieved.
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