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Customer cases

Customer cases

Selected work across factory transformation, design and operations.

MORE CASES

ELECTROCLASS — cas client Dillygence

After-sales operational performance: cut variability before adding resources

A fast-growing designer of automated storage solutions saw its after-sales service — a key part of its value proposition — come under strain.

ELECTROCLASS — cas client Dillygence
ELECTROCLASS — cas client Dillygence

Assembly standardization: turning an assembly bottleneck into continuous flow

The Factory Roadmap is a comprehensive assessment of an industrial site: it evaluates its maturity, ranks improvement levers, and lays out a phased roadmap, from quick wins to deeper transformation.

Wartner — cas client Dillygence

Automation: when machines are not enough

A high-end industrial laundry serving luxury hospitality had chosen to bounce back: a new, ultra-automated plant to quadruple its capacity and win an under-served market.

Authentic Material — cas client Dillygence

Cost price by activity: volume, the real lever to reach your target price

A high-end natural-materials maker runs three very different activities under one roof, while its pilot plant is almost frozen.

Agorespace — cas client Dillygence

Cut safety stock — and gain capacity without expanding

A growing industrial SME was steering its quality and procurement with no formalized method, while its firm order horizon was shorter than the lead time of its critical components.

ELECTROCLASS — cas client Dillygence

Doubling your production capacity without building a new site

When demand exceeds what a plant can produce, the reflex is to expand or build new. An industrial assessment often shows the opposite: part of the missing capacity is already there, blocked by flow organization rather than by machines. Here is the case of a mid-sized company in plant breeding that wanted to double its internal production capacity — and what an assessment revealed before any investment.

Mecapack — cas client Dillygence

Factory re-layout: rebuild around the operator, not the old plan

A packaging-machine manufacturer saw its historic site destroyed by a fire.

Exotec — cas client Dillygence

From modular cells to a flexible paced assembly line: produce more without expanding the factory

A French manufacturer of warehouse logistics robots had to multiply its volumes by nearly four by 2030 and consolidate production in a new building.

ELECTROCLASS — cas client Dillygence

From modular cells to a flexible paced assembly line: produce more without expanding the factory

A French manufacturer of warehouse logistics robots had to multiply its volumes by nearly four by 2030 and consolidate production in a new building. Its modular cell-based assembly, effective at the start, could no longer keep up: long cycle times, heavy reliance on technicians, large floor footprint, under-utilized workshop (TCUP ≈ 53% in 2026). The design study for a flexible paced assembly line — Design Optimizer mission — defined a quantified target model: produce more, on less space, with a much wider cadence range. The first gain is space.

Recup Auto — cas client Dillygence

Increase production capacity without expanding

An end-of-life vehicle treatment center saw its demand climbing, held up by its teams' commitment but stuck on craft-based methods.

Sarplast — cas client Dillygence

Industrial automation: tackle the waste before investing heavily

An automotive plastic-injection supplier, facing the renewal of its contract with a carmaker, seemed set on automating its line.

ELECTROCLASS — cas client Dillygence

Industrial diagnosis: absorb growth without suffering it

The Client, a rail specialist in floor assembly, is growing fast: in-housing activities, new programs, rising volumes. An industrial diagnosis carried out by Dillygence put words on the mounting tension — performance driven by teams' reactivity rather than stable processes — and mapped out a roadmap toward pull-based, paced and digitized management.

Toyota — cas client Dillygence

Industrial digital twin: recovering a workshop's lost throughput after a new model launch

An automaker had just introduced a new model on its existing body lines, altering the original layout — and throughput dropped.

Catoire — cas client Dillygence

Industrial digitalization plan: frame before you tool up

A precision-engineering SME had to digitalize three workstreams — HR, performance tracking (OEE) and a management dashboard — but had spent three years searching in vain for an OEE solution.

ELECTROCLASS — cas client Dillygence

Industrial facility layout study: target −33% lead time before building the new unit

A thermal equipment manufacturer doubled its business in four years and is about to commit to a major investment in new equipment worth €30–40M — to expand its heat exchanger production. The client chose to run an industrial facility layout study upstream of the investment: flow mapping, comparison of two layouts based on objective criteria, a targeted automation plan and an Industry 4.0 roadmap.

INTUIS — cas client Dillygence

Industrial footprint: arbitrating a footprint

An electric-radiator manufacturer, after merging several brands and a structural drop in volumes, had to present its majority shareholder with a clear view of its industrial options.

3DS — cas client Dillygence

Industrial layout: from flow chaos to one-piece flow (One Piece Flow)

A visual-identity expert challenged its industrial layout after acquiring a new ~550 m² workshop.

ELDIM — cas client Dillygence

Industrializing performance without losing your know-how

An optical-measurement instrumentation SME saw its activity grow strongly, but its production stayed in batches, with no pull flow, no standard work and no visual management.

ELDEC — cas client Dillygence

Industry 4.0 roadmap: stabilize before automating

An aerospace sensor and probe maker came out of a 360° diagnosis with a paradox: a mature strategy and organization, but the most manual production tool of its sector panel.

GMD — cas client Dillygence

Industry 4.0 strategy: knowing how to prioritize instead of launching everything

An automotive plastics supplier, already well rated after a 360° diagnosis, wanted to challenge its industrial improvement plan.

TECMAPLAST — cas client Dillygence

Inter-site logistics loop: absorbing +45% volumes without over-investing

An automotive plastics supplier saw a new project double the flows of its injection site and push its volumes by +45% in one year.

SPPP — cas client Dillygence

Labor cost: reaching the sector's standards without automating

An automotive subcontractor specialized in painting plastic parts, just acquired by an international group, had to prove its site's competitiveness against sector standards.

DPC — cas client Dillygence

Merging industrial sites: trap or opportunity?

A street-furniture and school-furniture group spread across three sites saw two comparable plants posting performance that differed by a factor of two.

BCF — cas client Dillygence

Modernizing an industrial site: more capacity, no CAPEX

Modernizing a historic industrial site rarely starts where you'd expect.

SCHLIGLER — cas client Dillygence

Operational excellence: staying competitive without offshoring

An aerospace subcontractor, highly manual and based in a high-cost country, saw its competitiveness threatened by a labor cost higher than its competitors'.

FACTEM — cas client Dillygence

Production line design: start over from value added

An aerospace and defense SME wins two contracts that require creating a new assembly line at short notice.

Nutrisens — cas client Dillygence

Production transfer: securing a repatriation after an acquisition

After acquiring a company in the same sector, a food-powder manufacturing activity had to be repatriated from a site abroad to a French group site.

Socofer — cas client Dillygence

Ramping up: moving from cells to the line

A manufacturer of rail maintenance vehicles had just won major contracts and was bidding on others.

RATP — cas client Dillygence

Re-laying out an industrial workshop: validate through simulation

A historic rail-maintenance workshop had to absorb a doubling of volumes and a new generation of bogies, in a building designed for another era: a workshop re-layout was called for.

U-Space — cas client Dillygence

Series industrialization: from one satellite a month to one a week

A satellite designer produced its pilots in an inherited plant with little industrial steering.

Pandrol — cas client Dillygence

Smart Factory: the case of a rail site

How a FACTORY ROADMAP diagnostic mapped the trajectory of a smart factory — by stabilizing flows before investing.

Catoire — cas client Dillygence

SME industrial diagnosis: the invisible waste that costs the most

This precision-engineering SME was seeing its margins tighten: falling activity and a payroll weighing heavily.