LEAN PROCESS BUILDING
Skills and Tools:
LEAN Methodology | 5 WHY Analysis | Pareto Analysis | Cross-Functional Leadership | Process Mapping | Stakeholder Influencing
90%
Shipment Success Rate
$100k
Saved Annually
40+
SKUs Launched
Saving over $100K Annually on New Product Releases to a Regulated Market, reaching 90% success launch rate, and restoring brand perception by retail partners and consumers.
SITUATION
New coffee machine launches at Philips were plagued by preventable delays that halted shipments for weeks. Critical errors like packaging labeled "milk breast pump" instead of "milk frother" or missing regulatory information created fractured execution, missed deadlines, and damaged retail partnerships. Additionally, poorly translated manuals were creating confusion amongst consumers and damaging brand perception. With over $100K lost annually to last-minute fixes across 50+ SKUs, the broken process was undermining brand credibility with retail partners and market momentum.
TASK
So, the task seems clear: transform the new product introduction (NPI) process to eliminate costly rework cycles on both sides: local warehouse and global backend and restore retailer and consumer confidence.
The goal was clear: achieve consistent, error-free launches while reducing localization costs and accelerating time-to-market. Success would be measured by shipment success rates, cost savings, and stakeholder satisfaction across markets.
ACTION
DIAGNOSTIC & ROOT CAUSE ANALYSIS
I started with a comprehensive LEAN diagnostic to uncover systemic breakdowns in the NPI process. I mapped the full product journey from R&D to market launch, conducted 5 WHY workshops to identify bottlenecks, and performed Pareto analysis to identify the most critical points contributing to failures.
The investigation revealed a lack of end-to-end ownership and any coherent process of which all involved parties are aware related to aligning documentation and assets with highly-regulated markets. Each department operated in silos without visibility into downstream impacts or accountability for final outcomes.
ACTION
CROSS-FUNCTIONAL SOLUTION DESIGN
The first challenge was to onboard all relevant stakeholders on this project. In a complex matrixed organization this meant identifying critical steps for the NPI, and departments responsible for each of them on the HQ and local levels. Then, I influenced my market Management Team to advocate the HQ top management to allocate time and leaders for the project on their side.
Succeeding on this mission (that deserves a separate post!) I facilitated cross-functional workshops where market, R&D, Regulatory and Engineering teams developed the proper process flow, identifying responsible functions at each step, repositories of information, estimated the workload and set milestone timelines. But most importantly of all - we made this process transparent to all the functions involved.
This collaborative approach ensured buy-in while addressing each team's specific pain points and establishing clear accountability frameworks.
ACTION
IMPLEMENTATION & MONITORING
Deployed standardized asset templates with pre-approved legal and marketing content, cutting local market adaptation time by 35%.
Created real-time dashboards visible across all functions for milestone tracking and early issue detection. Established clear process line that kept stakeholders from various functions aware or the contact persons and owners of information.
Established regular checkpoint reviews and escalation protocols to maintain momentum and prevent regression to old habits.
RESULTS
The transformation delivered immediate and lasting returns that elevated our entire launch capability. Shipment success rates rose from 40% to over 90%, while annual savings exceeded $100K from eliminated rework cycles. Improved launch quality strengthened brand perception and retailer confidence, allowing us to save budgets on delayed campaigns and unfulfilled deadlines. Most importantly, the scalable process became a competitive advantage that supported our market leadership position.
90%
SUCCESSFUL LAUNCHES FROM 40% PRIOR
$100k
SAVED ANNUALLY ON LAUNCH REFURBISHMENTS
50+
SKUs LAUNCHED WITH THIS PROCCESS
IMPROVED