Case Study: Fast-Tracking Innovation to Mass Production with Agile Project Management Office

Background:
A global leader in glass solutions was at a crossroads. Traditionally, its projects focused on well-defined product development with long life cycles and steady production processes. But a new innovation initiative demanded a bold shift. Agile product development, shorter life spans of just 1-2 years, and continuous updates became the new norm.

The Challenge:
This fast-paced environment brought major challenges. Project timelines were dramatically shorter, and objectives kept evolving. The company had to navigate change management in uncharted territory, qualify processes and production technology while operations continued, and launch new products while still manufacturing the previous generation. This juggling act added significant complexity.

The goal was straightforward: cut manufacturing costs to hit the target price for end customers. Achieving this required a smart, agile strategy that engaged all stakeholders and delivered rapid, practical results. The solution was the establishment of an agile Project Management Office (PMO).

The team kicked off with a thorough Total Cost of Ownership (TCO) analysis to identify cost-saving opportunities. This was followed by a robust action plan targeting production optimizations. A deep-dive manufacturing cost analysis revealed key cost drivers. Interactive Design for Manufacturing (DFM) workshops brought teams together to design products optimized for production.

Execution was driven by focused experimentation. Using systematic Design of Experiments (DoE), the team developed Proof of Concepts that unlocked critical insights for scalable mass production. Close collaboration with process engineers and Dev-Line operators ensured that experiments were relevant and concepts were validated effectively. Meanwhile, integrating TCO experts at headquarters kept cost control on track.

The results were immediate. The first Proof of Concepts were successfully completed. The action plan outlined clear, actionable steps for optimization. A detailed analysis of how different measures interacted enabled precise, effective implementation.

Coordinating product development, process optimization, and equipment procurement all at once was our greatest challenge. Traditional project structures simply couldn’t keep up. The agile approach empowered our team to take ownership and adapt swiftly, delivering results faster than we thought possible." – Project Sponsor, Global Glass Solutions Leader

By adopting an agile Project Management Office, the company responded quickly and decisively to a rapidly changing market. Innovation moved from concept to mass production faster and more efficiently. The payoff? Lower manufacturing costs and a strong foundation for future innovation. This case proves that agility is the driving force behind success in today’s dynamic markets.

By closely integrating product development, process optimization, and production planning, we were able to significantly reduce manufacturing costs while accelerating the transition from innovation to mass production. This approach has enabled the company to respond flexibly to market demands and secure sustainable competitive advantages." – Nicolai Rimmler, Consultant, Miebach.