+120
Countries of operation
Vertical Start-Up Reduces CAPEX Project Time by 60%
A global dairy and plant-based products company needed to accelerate CAPEX project execution across European operations. Together, we implemented the Vertical Start-Up approach on seven pilot projects totaling €120 million investment. The transformation established a structured methodology that fundamentally changed how teams collaborate from engineering through production ramp-up.
Industry: Food & Beverage
Service: Cost and Value Engineering
Service: Manufacturing
Service: Operational Excellence
Service: People and Organization
Our Client
This world food company specializes in a diverse range of products including waters, dairy and plant-based offerings.
Operating in over 120 countries with a significant presence in dairy and plant-based markets, the company reported €27.4 billion turnover in 2024. Its European operations span multiple production facilities requiring continuous investment in new production lines and facility upgrades.
€27.4B
Annual turnover
€300M
European CAPEX scope
+25
Projects at European level
“The method is effective, simple and team buy-in was immediate.
“
The Challenge
The company faced critical constraints in managing major capital investments across its European operations. Its existing approach created extended timelines that impacted competitiveness and return on investment.
Key operational challenges included:
- Extended ramp-up periods limiting ROI – Water business lines took three months to reach stable performance, while dairy operations required six months, delaying value realization from significant capital investments
- Siloed functions hampering project execution – Operational functions, engineering and supply chain worked independently during critical project phases, creating gaps in risk identification and mitigation that surfaced late in implementation
- Inconsistent project management across sites – Without standardized approaches or structured methodologies, each facility managed CAPEX projects differently, preventing knowledge transfer and best practice replication across the European network
Real Results Achieved Together
The Vertical Start-Up (VSU) implementation transformed how CAPEX projects are executed across European operations.
Working alongside local teams, we established a structured approach that dramatically accelerated project timelines while ensuring stable performance achievement.
60%
Reduction in start-up time
97%
Supplier concerns resolved before start-up
3
Months to stable OEE after start-up
Transformation Impact
- Established VSU Academy training, certifying experts across European operations
- Created comprehensive toolkit with methodologies, visual management tools and phase validation checklists
- Built sustainable capability through yellow belt and green belt certification programs
Our Approach
The transformation began with awareness seminars for steering committees at implementation sites. We trained and supported seven CAPEX project teams through the VSU method, testing the approach on water and dairy projects, including a complete factory conversion from dairy to plant-based production for one brand.
The VSU methodology introduced structured project management with seven phases, milestones and critical paths. Teams implemented visual management through Obeya rooms, enabling cross-functional collaboration from project inception. Risk identification and mitigation processes were embedded early with confidence indices and risk levels tracked throughout. We developed user-friendly toolkits including specific methodologies, checklists for factory acceptance tests and supplier management protocols.
To ensure sustainability we designed and implemented the “VSU Academy” with three training modules: awareness sessions for steering committees, yellow belt certification for team members and green belt training for future VSU leaders and engineering teams. Local trainers in France and Poland were certified to support ongoing deployment.
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Facing Similar CAPEX Execution Challenges?
- Struggling with extended ramp-up times that delay returns on major investments
- Seeking structured approaches to accelerate project delivery while ensuring quality
- Ready to build internal capabilities that transform how your teams execute capital projects
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