CASE STUDY SS-BM-IL-105 | Interim Leadership
Window & Patio Door Manufacturer Launch Recovery
Recovering Schedule, Driving Accountability, and Ensuring Launch Success
6+ Weeks
Cumulative Schedule Delay Recovered
2 Plants
New Product Launch Successfully Completed
On Time
Installation, Commissioning & Product Launch
Challenge
Critical New Product Launch Falling Behind Schedule Across Two Manufacturing Sites
- Critical Launch at Risk: A new vinyl window line spanning two major plants was significantly behind schedule on equipment installation, contractor coordination, and readiness milestones.
- Missed Installation Milestones: Ownership was unclear across engineering, operations, contractors, and equipment suppliers, making recovery priorities difficult to establish and execute.
- Limited Project Visibility: Inconsistent status reporting and the absence of an integrated master timeline prevented leaders from seeing delays and emerging constraints.
- Workforce Readiness Gaps: Operators and maintenance personnel lacked consistent training and readiness processes required for installation, commissioning, and successful production startup.
- Leadership and Communication Disruption: Leadership turnover and inconsistent cross-site communication weakened accountability and coordination between the Ohio and North Carolina operations.
Solution
Structured Interim Leadership and Lean Visual Management to Accelerate Execution
- Interim Project Leadership: Provided hands-on leadership across both manufacturing sites to stabilize execution, establish priorities, and create disciplined project governance.
- Gantt-Based Recovery Plan: Implemented an integrated master schedule with clear task ownership, critical milestones, dependencies, and specific recovery actions for delayed activities.
- Daily Tiered Accountability: Established structured daily meetings connecting contractors, engineering, operations, and production teams to identify issues and accelerate decision-making.
- Visual Project Controls: Deployed management boards and dashboards providing real-time visibility to schedule performance, constraints, responsibilities, and corrective actions.
- Standardized Launch Readiness: Implemented common readiness checklists and training matrices across both sites to ensure consistent installation, commissioning, and workforce preparation.
Results
Restored Schedule Performance and Established a Repeatable Launch Management System
- Six-Plus Weeks Recovered: Structured governance, visible accountability, and disciplined project management eliminated more than six weeks of cumulative schedule delay.
- Successful Two-Plant Launch: The project returned to schedule and the new vinyl window product line was successfully launched across both manufacturing facilities.
- On-Time Commissioning: Equipment installation and commissioning were completed on schedule, allowing commercial production and customer launch commitments to proceed as planned.
- Improved Cross-Functional Execution: Communication and coordination strengthened across operations, engineering, contractors, OEM partners, and the two plant leadership teams.
- Repeatable Launch Governance: Visual Lean tools, readiness standards, and daily accountability created a scalable launch-management model that could be replicated on future programs.