What began as a strategic impulse became a comprehensive transformation
Together with our customer, we have established an initiative that has rethought product development worldwide - with measurable success in terms of time-to-market, quality and costs.
Our client and the project
Comprehensive provider of integrated supply chain and material handling solutions
Turnover: € 11.5 billion
Employees: > 42,000
Client: CTO
Project duration: > 3.5 years
Consultant days: over 2,000 consultant days
Initial situation
Change begins with clarity - and the courage to question the status quo. This was precisely the starting point for the initiative.
KION is a leading global provider of forklift trucks, warehouse technology and supply chain solutions. In the context of increasing technological complexity, growing competitive pressure and increasing customer requirements, the company decided to comprehensively transform its development organization in 2018. The aim was to increase the efficiency and effectiveness of product development - while at the same time significantly reducing time-to-market.
A Group-wide change programme was launched with the KPDO - KION Product Development Optimization initiative. The focus was on the end-to-end optimization of all processes, methods and tools from product definition to series production - embedded in the KION Strategy 2027 .
Our contribution
Our strength lay not only in the concept - but in achieving real impact: faster, more efficiently and more reliably to market maturity.
CO Improve was a key partner in this transformation, from the initial idea to global implementation. Over a period of four years, we:
- initiated, set up and managed the project both methodically and operationally,
- designed the change using an agile framework,
- led or closely advised on seven key projects within the KPDO initiative,
- and actively supported the cultural change in the development organisation.
What makes our approach unique is that we didn't just deliver concepts, we lived and breathed implementation – through the close integration of strategy, expertise and change management.
Seven levers
Concrete improvements at the right points - effective, measurable, sustainable.
Seven levers for excellence in product development
- Product development process (PEP)
Development of a scalable, end-to-end PEP for all product groups - as a connecting structure for all units and regions. The new framework integrates classic and agile elements and enables systematic, fast and reliable development. In addition, the revised PEP has closed the gap between mechanical and plant engineering and thus contributed to the harmonization of the development of integrated intralogistics solutions. - Requirements management
Establishment of a new, group-wide requirements management system - with clear roles, processes, tools and training packages. Result: Greater maturity of product requirements and measurably fewer development loops. - Indicators & Metrics (Earned Value Management)
Establishment of a consistent key performance indicator system for managing development projects - including earned value management, maturity reports and dashboards for transparency in quality, costs and deadlines. - Customer Options
Harmonization and digitalization of the process for handling customer-specific options - across the Group and across brands. The result: faster response to customer requests while reducing manufacturing costs. - ETAP – External Tooling Approval Process
Development and implementation of a group-wide process for tool approvals - with role concept, guideline and MVP introduction. Result: Reduced costs and significantly more transparency in external tool procurement. - Digital Tools
Introduction of digital tools such as virtual mockups and maturity reports - to speed up decision-making and reduce material costs in early development phases. - Agiles Framework
Development and introduction of a scalable agile process model for complex development projects - including training, pilot projects and establishment of a change agent network.
The results
What we have achieved together: noticeable improvements in quality, time and costs.
The initiative was a complete success – in terms of content, culture and economics:
- -20% time-to-market with significantly increased SOP reliability
- Higher quality of requirements definition and tracking
- Significant efficiency gains in product development through transparent control and reduced interface losses
- Greater employee involvement through cross-functional teams and agile working methods
- Sustainable impact because methods, tools and culture were jointly established
Why the project works
The transformation at KION was more than just the introduction of new processes - it was a cultural change at the heart of product development. CO Improve shaped this change together with the client: systematically, pragmatically and with a strong focus on implementation. We were not only the driving force, but also part of the team - with a strong presence at international locations, a clear attitude and an eye for what works.