Real projects. Measurable results.

No theory. No polished case studies. Documented project results from industry - with concrete KPIs, real challenges, and solutions you can follow step by step.

Tier-1 Automotive Supplier - Serial Ramp-up
Launch Management · Task-Force · CZ Plant
Tier-1 Automotive Supplier - Full Program
€120M program · DE & USA · End-to-end program leadership
Tier-1 Automotive Supplier - Interior
Task-Force Management · Ramp-up · New surface technology
Pharma Machinery - MPM Software
Project Leadership · MPM Software · 1,700 users
Tier-1 Automotive Supplier - PMO Build
Division Leadership · PMO Build · €600M revenue · 5 sites
Tier-1 Automotive Supplier - Center Console
Task-Force Management · SOP pulled forward · +9% EBIT margin
Tier-1 Automotive Supplier - Autonomous Shuttle
AD System Program Leadership · Level 4 · 14+ agile teams
Pharma Machinery Builder - Modularization
Program Steering · Modular Product Architecture · Blister Packaging
Pharma Filling Line Manufacturer - PMO Build
Central Project Steering · MPM Tool · Portfolio Governance
ISO 9001 certified
TISAX assessed
160+ projects delivered
Ø 4.8 / 5 client satisfaction
Task-Force Einsatz Automotive Tier-1 Tier-1 Automotive Supplier · CZ Plant

From zero days of supply to stable serial delivery - in 2 months.

A Tier-1 supplier was facing line shutdown at the OEM. Multi-million penalties were on the table, client trust was gone, the company's financial stability was at risk. Evolve took over bottleneck management in task-force mode.

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Situation & Challenge

Daily risk: line shutdown at the OEM

A Tier-1 automotive supplier was running the ramp-up of two strategic large programs for a German OEM. The situation had escalated: supply security was failing, quality was poor, the OEM relationship was broken. Line shutdown was a daily threat - with multi-million contractual penalties.

Zero days of supply at the OEM - imminent line shutdown risk
Scrap rates up to 30% in production
Frequent tool damage interrupting serial production
Overwhelmed logistics and shipping
Capacity bottlenecks in production
Additional bottleneck via the Q-Wall
Production planning ignored OEM coverage windows
Lost client trust at the OEM
Goals

Secure delivery. Cut costs. Win back trust.

The priorities were clear: First prevent the looming line shutdown, then stabilize the process chain and eliminate special freight - and finally rebuild OEM trust through measurable improvements.

Evolve Approach

Task-force mode: bottleneck management along the entire chain

Evolve took over bottleneck management for both large programs and worked systematically from treating symptoms to fixing root causes - along the entire process chain from production through quality inspection to shipping and transport.

Took over bottleneck management for two critical ramp-up projects
Planning, prioritization, and tracking of deliveries via special freight
Established communication structure in task-force mode
Root-cause analysis across production, quality, shipping, transport
Switched freight forwarder and replanned special shipments
Reinforced critical areas with additional staff
Professional reporting and communication to the OEM
Optimized production planning around OEM coverage windows
Increased lot sizes to reduce changeovers
Steered optimization of serial tools and equipment
Results & Outcomes

From crisis mode to stable serial delivery

Within 2 months, delivery was stabilized, special freight eliminated, and client trust restored. The financial impact was measurable immediately.

0 → 5 days
Days of supply at the OEM
in just 2 months
€200,000
Monthly savings
from eliminating special freight
–15%
Reduction of critical
cycle times
+5%
OEE improvement
100%
Stable serial
delivery achieved
Client trust
restored
Line shutdown prevented
Special freight eliminated
Standard delivery established
OEM trust regained
End-to-end Program Leadership Automotive Tier-1 €120M Program Tier-1 Automotive Supplier · Germany & USA

From crisis to success - how we rescued a €120M program.

A leading Tier-1 supplier was facing its biggest project ever: development and industrialization of frunks and engine bay covers for a German premium OEM. What began as a growth program turned into an existential test. The OEM was already considering alternative suppliers.

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Situation & Challenge

A program on the brink of failure - across three continents

The challenge was multi-layered: massive development delays, an overwhelmed team, constant concept changes from the OEM, and a parallel monumental task - the complete rebuild of the US serial plant. At the same time, client trust had already eroded through problems in previous projects.

Massive delays in the development phase
Overwhelmed team - complexity exceeded capacity
Constant OEM concept changes - a never-ending flood of revisions
Lost client trust due to issues in previous programs
Global coordination across 3 time zones (DE/USA) with cultural barriers
Critical technical requirements not met
Parallel full rebuild of the US serial plant: machines, warehouse, intralogistics, assembly
OEM was already considering alternative suppliers
Goals

Save the program. Transform the plant. Rebuild OEM trust.

The goals were clearly defined: get the program back on the OEM timeline, meet every technical requirement through PPAP, simultaneously enable the US site for serial production - and rebuild the client relationship through reliability. All within the existing budget.

Evolve Approach - Phase 1: Rapid Stabilization

Create structure. Regain control. Master the flood of changes.

Evolve took over end-to-end program leadership and immediately established a clear project structure with defined communication architecture. In parallel, an accelerated change management system was introduced to systematically work through the OEM's flood of changes.

Built a clear project structure and communication architecture
Realistic master schedule synchronized with OEM milestones
Accelerated change management to rapidly process the flood of changes
Professional reporting to leadership and OEM
Evolve Approach - Phase 2: Technical Excellence

Task-force teams for critical technical challenges

Dedicated task-force teams were set up for the most critical technical requirements - climate cycling, watertightness, dynamic load. In parallel, rigorous supplier tracking for injection molding tools, assembly equipment, and bought-in parts secured every quality gate through PPAP.

Task-force teams for climate cycling, watertightness, dynamic load
Rigorous supplier tracking for tools, equipment, and bought-in parts
Secured every quality gate through PPAP
Proactive escalation and risk management
Evolve Approach - Phase 3: Industrialization & US Plant Enablement

Complete transformation of the US plant to serial readiness

Alongside development, Evolve steered the complete transformation of the US site - from procuring new injection molding machines during live operations, to building a new high-bay warehouse, to designing and realizing an entirely new assembly area. This end-to-end steering of development and industrialization is what sets Evolve apart: we think the product from first concept through to running production.

Procurement, installation, and commissioning of new injection molding machines during live operations
Planning and build of the high-bay warehouse incl. intralogistics reorganization
Design and realization of the new assembly area - layout through commissioning
Synchronization of new systems with existing production flows
Securing the on-time ramp-up curve for serial start
Optimization of DE/US team collaboration across all functions
Cost-down measures with zero quality compromise
Building local competence in the US team for sustainable serial support
Results & Outcomes

€120M program saved. Plant transformed. OEM impressed.

The program was completed on time and within budget - despite massive change requests and the parallel plant transformation. The result: a serial-ready US site, technically flawless products, a satisfied OEM, and secured follow-on orders.

€12M
EBIT improvement through
intelligent cost management
100%
Deadlines met -
PPAP delivered on time
✓ Budget
Held despite massive
changes & plant rebuild
3 time zones
DE/USA successfully
synchronized
SOP ✓
Successful serial start
with stable processes
Follow-on orders
OEM highly satisfied -
follow-on orders secured
Budget held
All deadlines met
Technical perfection
Plant serial-ready
Stable SOP
OEM trust restored
Task-Force Management Automotive Tier-1 Tier-1 Automotive Supplier · Center Console

From ramp-up chaos to stable serial production - scrap reduced by 70%.

A Tier-1 supplier for vehicle interiors - with plants in three EU countries - was stuck in the ramp-up of a center console for a German premium OEM: significant delay, immature tooling, failing parts supply. Evolve took over task-force leadership.

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Situation & Challenge

Ramp-up escalated: immature tools, 50% scrap, OEM unhappy

The project to develop and industrialize a center console was in ramp-up - with significant delay and insufficient maturity in tools and parts. Parts supply to the OEM was failing, quality issues were severe.

Insufficient plant output during ramp-up
Difficulties supplying the OEM
Quality issues and scrap rates up to 50%
Insufficient maturity of production tooling
Inadequate part quality
Technical difficulties introducing a new surface technology
Goals

Stabilize ramp-up. Secure quality. Win back trust.

Priority one: secure OEM parts supply and defuse the escalation. Then stabilize production processes, master the new surface technology, and successfully complete process and product validation.

Evolve Approach

Task-force leadership: restructuring, quality offensive, stakeholder management

Evolve took over task-force leadership in the ramp-up and restructured the project from the ground up - from schedule management through team integration to professional client management that defused the escalation.

Took over task-force leadership in the center console ramp-up
Restructured the project: schedule management, communication, reporting
Defined and steered optimization measures to achieve required part quality
Improved integration of engineering and ramp-up teams
Professional client and stakeholder management for de-escalation and trust rebuild
Results & Outcomes

In 4 months: de-escalation, serial ramp-up, new technology mastered.

Within four months the project was stabilized, the OEM escalation defused, and serial production with the new surface technology successfully ramped up. The client relationship was sustainably improved.

–70%
Reduction of
scrap rates
+80%
Improvement of OEM
parts supply
4 months
Stabilization &
OEM de-escalation
100%
Process sign-off, product
& process validation
SOP ✓
Successful serial start
new surface technology
Internal capacity freed
for strategic topics
OEM escalation resolved
Scrap reduced by 70%
Serial production launched
New technology mastered
Client trust restored
Project Leadership Machinery Leading Pharma Machinery Builder · Pharma Machinery

From 200+ uncontrolled projects to transparency on demand - with 1,700 active users.

A leading pharma machinery builder - manufacturer of filling and packaging equipment for liquid and powder pharmaceuticals - needed multi-project management software to handle its rapid growth. Evolve took over project leadership for the enterprise-wide rollout.

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Situation & Challenge

200+ active projects, no central control, no transparency

Rapid company growth had outpaced existing structures. With a portfolio of 200+ active projects, there was no central system for steering, resource planning, or progress tracking. Leadership demanded "project transparency on demand" - reality was nowhere close.

200+ active projects without central control or unified reporting
Rapid company growth overwhelmed existing PM structures
Targeted efficiency improvements required
No enterprise-wide resource visibility
Leadership without real-time portfolio visibility
Goals

One system. Full transparency. 1,700 users enabled.

Introduce a powerful multi-project management software that covers every relevant business area, integrates seamlessly with existing systems, and delivers real value from leadership down to the individual project manager.

Evolve Approach

Project leadership from requirements to enterprise-wide rollout

Evolve took over project leadership for the entire rollout - from requirements management through software selection to deployment and enablement of every user. With clear structure, professional stakeholder management, and a blended team of internal and external resources.

Built the project and communication structure
Built and steered the master schedule with predefined milestones
Authored the software requirements and led the selection process
Led the project team across internal and external resources
Professional stakeholder management to deliver requirements from every business area
Results & Outcomes

Enterprise-wide rollout. 1,700 users. Full transparency.

The MPM software was successfully rolled out across every relevant area. 1,700+ users were trained and enabled. Leadership now has the real-time view of the entire project portfolio they demanded.

1,700+
Active users trained
and enabled
200+
Projects unified
in one system
100%
Integration with
existing systems
Enterprise-wide
resource visibility
Unified project
steering
Transparency on
demand for leadership
MPM software rolled out enterprise-wide
1,700+ users enabled
Full portfolio transparency
Resource planning optimized
100% system integration
PMO Build & Division Leadership Automotive Tier-1 Tier-1 Automotive Supplier · International

Division grown by 70%, EBIT margin lifted by 5% - at €600M revenue.

A Tier-1 automotive supplier - vehicle interiors manufacturer with plants in three EU countries - had to fundamentally transform its international PM division of ~30 staff across five sites: deliver new projects, improve EBIT margins, and decentralize the division. Evolve took over division leadership.

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Situation & Challenge

Too few resources, no structures, escalations at every level

The international PM & Advanced Quality Engineering division faced a multi-front challenge: many newly won projects had to be delivered, but the resources, processes, and capabilities were missing. Schedule slippage and customer escalations were daily business, budgets were routinely overrun.

Insufficient resources for the many newly won projects
Missing PM processes and capabilities in the team
Insufficient understanding of customer requirements
Regular schedule slippage and customer escalations
Frequent project budget overruns
Missing transparency over the project portfolio
Centralized approach without customer proximity
Goals

Scale the organization. Improve EBIT. Decentralize the division.

The goals were threefold: First, build the PM division to professionally deliver the newly won projects. Second, significantly improve EBIT margins across the project portfolio. Third, decentralize the division through a multi-site approach close to customers.

Evolve Approach

Division leadership taken over: from recruiting to PMO rollout

Evolve took over division leadership and built the PM organization systematically - from recruiting through process definition to the rollout of a standardized PMO with steering committee, project cockpit, and training programs.

Took over international division leadership PM & Advanced Quality Engineering
Intensive recruiting of new project leaders and AQE incl. sharpening of role profiles
Operational steering of the entire project portfolio
Introduction of the Project Steering Committee and Project Cockpit
Definition and rollout of the PMO
Sharpening of processes and the Product Development Process (PDP)
Restructuring and decentralization through a multi-site approach
Results & Outcomes

Division grown by 70%. €600M revenue steered. EBIT target band reached.

The PM division was successfully scaled from ~30 to ~50 staff, the PMO rolled out, standardized systematics introduced, and the division decentralized across five sites in three countries. EBIT margins across the portfolio improved by ~5%.

+70%
Growth of the
PM division
+5% EBIT
Margin improvement
across the portfolio
€600M
Total revenue of
the project portfolio
5 sites
Decentralized across 3 countries,
close to customers
€90M
Total project portfolio
budget steered
PMO ✓
Strategically defined,
organized, and rolled out
PMO successfully rolled out
Division scaled by 70%
EBIT target band reached
Multi-site decentralization complete
PM training programs established
Customer relationships stabilized
Task-Force Management Automotive Tier-1 Tier-1 Automotive Supplier · Center Console Program

Market launch pulled forward by 5 months - EBIT margin lifted by 9%.

A Tier-1 supplier for vehicle interiors (center consoles, pillars, decors) was in a critical phase of a strategic program. The OEM pulled SOP forward by 5 months while project EBIT margin was under pressure. Evolve took over program leadership in task-force mode.

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Situation & Challenge

Pulled-forward SOP, high cost pressure, new technology - all at once

The center console program for a German premium OEM was in a critical phase. The OEM was driving a strategic earlier-to-market goal - SOP was pulled forward by 5 months. At the same time, project EBIT margin was under pressure and demanded rigorous change and targeted cost-down management.

Extremely tight schedule with a clear mandate to pull SOP forward by 5 months
Project team not fully staffed
Technical and organizational overlaps within the program
Unclear overall strategy at program level
Extremely high client attention at board level (showcase project)
Significant cost pressure from the OEM due to part prices well above benchmark
Industrialization of a technology new to the company (laminating)
Goals

Pull SOP forward. Secure margin. Get the new technology running.

The strategic goals were clearly defined: hold the pulled-forward SOP date, secure project EBIT margin through rigorous change and cost management, successfully industrialize the new laminating technology - and rebuild OEM trust at board level.

Evolve Approach

Program leadership in task-force mode with clear structure

Evolve took over program leadership in task-force mode, built a clear program organization with three sub-projects, and established rigorous schedule, cost, and supplier management while handling client engagement at board level.

Program leadership in task-force mode for the center console program
Built the program organization with 3 sub-projects and clearly defined goals
Established communication in task-force mode (daily meetings)
Introduced "Critical Path Schedule Management" to accelerate the timeline
Initiated and steered the cost-down initiative
Client engagement at board level (reporting, management meetings)
Structured supplier steering and very tight supplier management
Results & Outcomes

Strategic client goal achieved - largest follow-on order in company history

The OEM's strategic goal was achieved, margin secured, new technology successfully launched - and the rebuilt OEM trust led to the largest follow-on program in the company's history.

–5 months
Earlier market launch
(strategic OEM goal)
+9%
Increase in
project EBIT margin
SOP ✓
Successful industrialization
of new laminating technology
3
Structured sub-projects
within the program
Client trust rebuilt
at board level
Follow-on order
Largest program in
company history
Strategic client goal achieved
Margin sustainably improved
New technology mastered
Client trust expanded
Largest follow-on order won
Program Leadership Autonomous Driving · Level 4 Global Tier-1 Automotive Supplier · AD System

Autonomous L4 shuttle successfully on the road - project budget reduced by €10M.

As part of its future strategy, a globally leading Tier-1 supplier was developing an autonomous Level 4 shuttle including the complete AD system and software. The highly complex program demanded an integrated schedule, a clear operating model, and maximum transparency - amid enormous technical and organizational complexity. Evolve took over program leadership for the AD system.

!
Situation & Challenge

Maximum technical complexity meets an unclear operating model

The L4 shuttle program was one of the most technically demanding initiatives in the company. Autonomous driving, safety requirements, and the program's sheer size created enormous complexity. At the same time, the agile operating model was new, roles were unclear, and classic HW interfaces and agile SW teams were running in parallel rather than together.

Enormous project complexity - technical and organizational
Schedule slippage on the homologation of the first self-driving prototype
Unclear goals and prioritization of individual SW features for autonomous driving
Unclear role understanding and slow collaboration in the new agile model
Critical HW interfaces working in classic mode - friction losses with agile SW teams
Insufficient technical maturity and test depth
Runaway project costs
Goals

Create transparency. Sharpen the operating model. Enable the demo drive.

The goals were clear: build an integrated schedule across the entire shuttle program, get the hybrid operating model between agile SW development and the classic HW world to actually work, enable the first demo drive on public roads - and at the same time get runaway costs under control.

Evolve Approach

AD System program leadership with hybrid methodology and 14+ agile teams

Evolve took over program leadership for the AD system, established an integrated schedule across the entire shuttle program, and brought 14+ agile teams totaling 180 members into an optimized way of working. Hybrid methodology, clear governance, rigorous cost management.

Took over program leadership for the AD system
Built an integrated schedule across the entire shuttle program incl. AD system & software
Established a hybrid methodology - agile SW development bridged with classic HW approach
Optimized 14+ agile teams (180 members) - role clarity, coaching, goal alignment, tighter planning
Lifted transparency through structured governance and clear accountability
Prepared and steered the first demo drive on public roads
Rigorous cost management to reduce the project budget
Results & Outcomes

First demo drive successful - budget reduced by €10M

The autonomous shuttle successfully completed its first demo drive on public roads. The integrated schedule, sharpened operating model, and lifted transparency brought the highly complex program back into stable waters - with significant cost reduction along the way.

−€10M
Reduction in
project budget
L4 ✓
First demo drive on
public roads
14+
Optimized agile teams
(180 members)
100%
Integrated schedule
across the full program
Hybrid
Agile SW + classic HW
successfully integrated
Transparency and governance
sustainably established
Integrated schedule established
Operating model sharpened
First L4 demo drive successful
Project budget reduced by €10M
Program Steering Pharma Machinery Leading Manufacturer of Blister Packaging Lines · Pharma Machinery

From a burned-out modularization project to a robust product architecture - acceptance restored.

A leading manufacturer of blister packaging lines for the pharmaceutical industry was in a critical phase: a multi-year modularization project with repeated iteration loops, high complexity, and a clear loss of acceptance across the organization. Evolve took over program steering and brought clarity, structure, and stakeholder alignment.

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Situation & Challenge

A burned-out modularization project of high strategic relevance

The goal was a function-oriented, modular product architecture. But historically grown one-off and special solutions, years of iteration loops, and a strongly engineering-driven project team without sufficient stakeholder involvement had led to massive complexity and a clear loss of acceptance. The project was strategically central - but organizationally stuck.

Multi-year project with repeated iteration loops and a "burned-out" status
Conflict between rigorous standardization and historically grown special solutions
Strongly engineering-driven team without involvement of sales, service, production
No overarching development strategy to integrate existing solutions
High complexity, clear loss of acceptance across the organization
Sufficient technical resources but no structured steering or prioritization
Goals

Create clarity. Stabilize the architecture. Win back acceptance.

The goals were clearly defined: establish full transparency over status, target picture, and decision needs. Develop a robust, function-oriented modularization strategy as the foundation for future product generations. And re-position the project organizationally - through real stakeholder alignment across all functions.

Evolve Approach

Program steering: structure, decision logic, stakeholder alignment

Evolve took over program steering and introduced a structured decision logic for evaluating, integrating, or eliminating special solutions. In parallel: building a cross-functional target picture, rigorous project and schedule management, and active change management to restore internal acceptance.

Took over program steering for the modularization project
Structured decision logic for evaluating, integrating, or eliminating special solutions
Established a cross-functional target picture with all relevant stakeholders
Rigorous project and schedule management with clear milestone structure
Facilitation and resolution of central technical questions to reduce complexity
Built a transparent communication and governance structure
Active change management to restore internal acceptance
Results & Outcomes

Architecture stabilized. Stakeholders aligned. Project strategically re-positioned.

Full transparency over project status, target picture, and decision needs was established. A robust modularization strategy was developed, central technical questions were resolved, and a stable architecture concept was defined. Internal acceptance was restored - the project was strategically re-positioned and the foundation for sustainable cost reduction through standardization was laid.

100%
Transparency over status,
target picture, and decisions
Stable
Architecture concept
defined and validated
Robust modularization
strategy developed
Cross-functional
Sales, service, production
actively engaged
Internal acceptance
restored
Scale effects
Foundation for sustainable
cost reduction laid
Full project transparency established
Robust modularization strategy developed
Stable architecture concept defined
Stakeholders cross-functionally engaged
Internal acceptance restored
Project strategically re-positioned
PMO Build Pharma Machinery International Manufacturer of Pharmaceutical Filling Lines · Pharma Machinery

From decentralized project chaos to a centrally steered portfolio - PMO as the backbone of the project landscape.

An international manufacturer of pharmaceutical filling lines faced the challenge of efficiently steering a growing project landscape across multiple parallel customer and development projects. Evolve designed and built a central Project Management Office - including governance, reporting, and the rollout of a multi-project management tool.

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Situation & Challenge

Growing project landscape, no central steering authority

With a growing number of projects and rising complexity, there was no central authority for overarching steering. Project management was handled decentrally and inconsistently. Transparency over status, resources, and priorities was missing. In parallel, a multi-project management tool was to be introduced - but without defined processes or governance.

No established PMO - project steering decentralized and inconsistent
No transparency over project status, resource allocation, and priorities
Multiple parallel customer and development projects with high interdependencies
Different PM methods and standards across functional areas
Limited steering capability at portfolio level, no clear prioritization
MPM tool rollout planned but without defined processes or governance
High coordination overhead between engineering, production, sales, service
Resource bottlenecks and conflicting priorities not systematically addressed
Goals

One PMO. One framework. One steered portfolio.

The goal was to build a central Project Management Office as the steering authority for the entire project landscape. Standardized PM processes, end-to-end reporting, structured resource management, and the successful rollout of a multi-project management tool - all embedded in a robust governance structure.

Evolve Approach

PMO build from concept to organizational anchoring

Evolve designed and built a central PMO - with clear roles, responsibilities, and governance. Definition of a standardized PM framework, harmonization of project planning, end-to-end reporting, structured resource management - and support for the organizational change process to anchor the PMO sustainably.

Designed and built a central PMO (roles, responsibilities, governance)
Defined a standardized PM framework (methodology, templates, KPIs, reporting)
Harmonized and standardized project planning (schedule, resources, budget)
Built end-to-end reporting at project and portfolio level
Implemented structured resource management across all projects
Supported the organizational change process to anchor the PMO
Results & Outcomes

Central PMO established. Portfolio actively steered. Best practices anchored.

A central PMO was established as the steering authority for the entire project landscape. Transparency over all running projects - status, risks, resources - increased significantly. The project portfolio is now clearly prioritized and actively steered. Standardized PM processes and a unified way of working across all areas lay the foundation for scalable growth.

Central PMO
established
Portfolio
Actively steered
and prioritized
+
Significantly higher
project transparency
Standard
Unified PM processes
across all areas
Resource conflicts
systematically reduced
Scalable
Foundation for efficient
future delivery
Central PMO established
Portfolio transparency established
Prioritization actively steered
PM processes standardized
Resource conflicts reduced
Best practices sustainably anchored

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