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Crisis-Driven Organizational Transformation for a Medical Manufacturer During COVID-19
Industry : Medical
Category: Manufacturing & Distribution
Location : France
AVEL Consulting supported a medical equipment manufacturer in France in quadrupling its production capacity within six months during the COVID-19 crisis. Through comprehensive process redesign, governance improvements, and robust change management, the company met surging demand while maintaining operational stability and employee well-being.
Problem
In March 2020, as the COVID-19 pandemic escalated, the client, producing medical equipment (surgical masks) and personal protective equipment (respiratory masks and PPE), was requisitioned by the French government. The company faced:
- Total Production Reallocation: All output redirected to the French state, halting regular client services.
- Global Supply Shortages: Severe scarcity of raw materials essential for medical products.
- Demand Explosion: Soaring needs from hospitals and healthcare providers.
- Structural Strain: Inadequate processes, tools, and organization for 4x production growth.
- Employee Fatigue: High stress and exhaustion due to pandemic pressures.
Approach
Solution
Key initiatives included:
Process & Tools
- Creation of critical processes: executive decision-making, crisis cell, product allocation, S&OP, and demand planning.
- Development of real-time dashboards tracking KPIs across HR, Production, Supply Chain, IT, Quality, Finance, Sales, and Customer Service.
- New tools for material and product allocation, demand planning, and production forecasting.
Governance & Culture
- Establishment of daily executive meetings for priority alignment.
- Enhanced internal communications to keep employees informed and engaged.
- Redesign of team roles and responsibilities across Supply Chain, Production, Sales, Customer Service, and Procurement.
- Creation of new departments and rapid recruitment to support growth.
- Employee wellness initiatives: paid leave, identified backups, social events.
Results
- Production Capacity: 4x increase in output within six months.
- Workforce: Doubling of employee headcount.
- Risk Management: Mitigation plans implemented and maintained.
- Sustainability: Processes stabilized, roles clarified, and governance strengthened.
- Lasting Impact: Several years later, improvements remain in place, with continued process enhancements and adherence to best practices.
Production Capacity: 4x increase in output within six months.
Workforce: Doubling of employee headcount
Risk Management: Mitigation plans implemented and maintained
Sustainability: Processes stabilized, roles clarified, and governance strengthened
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AVEL Consulting conducted a multi-week diagnostic, combining interviews with leaders and staff and in-depth reviews of processes and tools. Immediate “quick wins” were actioned to build momentum, while a deeper roadmap was developed to address core challenges across: