Projects
Our comprehensive project list provides an overview of the wide range of initiatives we have supported across regions, products and markets. It reflects the breadth of our experience in the aluminium industry. Selected case studies highlight specific examples of how we help aluminium companies address complex strategic, operational and technological challenges — combining deep industry knowledge, structured analysis and hands-on execution to deliver sustainable, practical results.
Project List
Strategy, Corporate Development & MA Support
Sales & Business Development
Project Development & Execution
Operations, Excellence & Readiness
Recycling & Sustainability
Technology, Innovation, Digitalisation
Strategy, Corporate Development & M&A Support
| Remelting, Casting, Rolling and Finishing of Plate and Shate | Carve-out, creation of a competitive stand-alone structure in a private equity context, strategy process and turn-around management |
Southern Europe |
2017 – 2019 |
| Remelting, Casting, Rolling and Finishing of Aluminium Rolled Products | Post-merger integration of an aluminum plant, including projects for production, maintenance, and related investments | Southern Europe | 1999 – 2007 |
| Remelting, Casting, Rolling and Finishing of Plate and Shate | SME for top-tier global consulting firm for feasibility study in the framework of the Saudi “Vision 2030” | Middle East | 2019 – 2020 |
| Remelting, Casting, Rolling and Finishing of Aluminium Rolled Products | Technical Due Diligence supporting the acquisition of an European Integrated Aluminum Rolling Mill by Private Equity | Central Europe | 2020 |
| Casting | Co-Program Lead of strategic investment (CAPEX) project in large dimension billet capability. | Central Europe | 2018 – 2019 |
| Casting, Rolling, Extrusion | SME in various divestments and acquisitions | Europe | 2021 – 2022 |
| Rolling, Painting | Project lead in strategic partnership negotiations with a lacquer and paint supplier concerning new supply and manufacturing agreements | Central Europe | 2021 – 2022 |
| Remelting, Casting, Rolling and Finishing of Plate and Shate | Development of Go-To-Market strategy, sourcing strategy, pitch-deck development, sales support, pricing strategy and benchmarking | Middle East | 2025 |
| Remelting, Casting, Rolling, Extrusion and Forging | Lead Integration of a new acquired large scale organization into a US company. | Eastern Europe | 2005 – 2007 |
| Remelting, Casting, Rolling, Extrusion and Forging | Interim management as Executive Director Operations | Eastern Europe | 2005 – 2007 |
| Remelting, Casting, Rolling and Finishing of Aluminium Rolled Products | Established greenfield plant & Interim Management (Operations Director) | Middle East | 2013 – 2014 |
| Interim Management | Interim Management (CEO), automotive supplier | Central Europe | 2022 – 2023 |
| Remelting, Casting, Rolling and Finishing of Aluminium Rolled Products | Due diligence with assessment of organization, assets, capabilities, CAPEX and business plan, define potentials to improve. | Europe | 2021 |
| Remelting, Casting, Rolling and Finishing of Aluminium Rolled Products | Due diligence with assessment of organization, assets, capabilities, CAPEX and business plan, define potentials to improve. | Southern Europe | 2021 |
| Remelting, Casting, (Foil) Rolling | Due diligence with assessment of organization, assets, capabilities, CAPEX and business plan, define potentials to improve. | Southern Europe | 2022 |
| Remelting, Casting, Rolling and Finishing of Aluminium Rolled Products | M&A SME: improvement of marketing, sales, products, operational performance and partnerships | Central Europe | 2024 |
| Remelting, Casting, Rolling and Finishing of Aluminium Rolled Products | Due diligence with assessment of organization, assets, capabilities, CAPEX and business plan, define potentials to improve. | Eastern Europe | 2000 – 2020 |
| Components Manufacturing | Interim Managing (Director), component manufacturer | North America | 2001 |
| Rolling | Restructuring and revamping of an aluminum rolling mill, execution of an investment program | Europe | 2004 – 2005 |
| Extrusion – Hard Alloy | Project lead: acquisition of an Italian extrusion company | Europe | 2013 |
| Components Manufacturing | Project lead: strategy process, aquisition of a German aerospace machining company | Europe |
2021
|
| Rolling | Commercial strategy development | Europe |
2024
|
| Extrusion – Hard Alloy | Corporate strategy and restructuring plan | Europe | 1998 – 1999 |
| M&A | Project lead: acquisition (minority shareholding) of a medical engineering company | Europe | 2000 – 2001 |
| Components Manufacturing, Machining | Start and develop several companies, elaboration of corporate strategies, site development concepts and lay out | Europe | 2001 – 2004 |
| Extrusion – Hard Alloy | Elaborate and execute a commercial strategy and product mix optimization | Europe / Asia | 2005 – 2009 |
| Components Manufacturing | Project lead: post-merger integration | Europe | 2021 – 2022 |
| Rolling | Corporate strategy development and execution (Head of PMO) | Europe | 2021 – 2023 |
| Components Manufacturing, Machining | Development of a corporate strategy including an investment program; elaboration of. Asiet development concept and implementation plan | Europe | 2022 – 2023 |
| Extrusion – Hard Alloy | Managing Director: P&L responsibility (€50M), investment execution (€12M); restructuring and stabilization of organization | Southern Europe | 2011 – 2012 |
| Extrusion – Hard Alloy | Commercial Director: product & sales strategy development; set-up of dedicated sales and inside sales team | Southern Europe | 2010 – 2011 |
Sales & Business Development
| Casting, Rolling, Cold Rolling and Finishing | Project lead in developing growth strategy for aerospace sheet | Central Europe | 2017 – 2018 |
| Extrusion – Hard Alloy | Project lead in developing growth strategy for aerospace extrusions | Central Europe | 2017 – 2018 |
| Casting | Aluminum-lithium casting capacity review. Pre-study for casting capacity expansion options | Central Europe |
2017
|
| Casting | Project lead in developing growth strategy for aerospace sand casting products and business unit | Central Europe | 2019 |
| Casting, Rolling, Extrusion | Driving aluminum-lithium business development outside aerospace | Global |
2018
|
| Market Intelligence | Aerospace market intelligence lead/SME | Global |
2017 – 2020
|
| Rolling, Extrusion | Developing new sales channels, optimizing product mix, establishing product management teams, developing and expanding business volume, restructuring sales teams, increase product focus | Europe / North America / Asia |
1995 – 2022
|
| Rolling | Starting and developing sales organization in Japan for the Asia Pacific region | Asia Pacific |
1995 – 1998
|
| Extrusion – Hard Alloy | Implementation of business development organization. Creating “Growth Funnel” for new products, market | Europe / Asia | 2006 – 2008 |
| Rolling | Developing export organization, growing sales volume | Europe / Asia | 2008 – 2009 |
| Commercial, Business Development | Growing and developing sales network of GRP pipes) | Europe / Asia | 2009 – 2012 |
| Extrusion – Hard Alloy, Forging – Hard Alloy, Qualification, Business Development, Account Management | Global Account Manager for Aerospace OEM: qualification management of advanced forgings & extrusions; Long Term Agreement negotiations; business development of new alloy products | Global | 2009 – 2010 |
| Extrusion – Hard Alloy, Qualification, Business Development, Account Management | Application Engineering & Business Development: alloy and product qualification across Aerospace, Automotive, Oil & Gas and Defense; hard alloy extrusion product development; new market implementation | Europe / Asia | 2006 – 2009 |
| Extrusion – Hard Alloy, Forging – Hard Alloy, Qualification, Business Development, Account Management | Business Development Manager: product development & qualification of forgings and extrusions; transfer of aerospace alloys to automotive; technical support for Al-Li casthouse investment ($100M) /td> | Global | 2013 – 2019 |
| Business Development, Product Development, Qualification | Business Development Manager Advanced Alloys: alloy product development & qualification; transfer of aerospace alloys to automotive and industrial; market & technology review | Global |
2019
|
| Casting, Rolling, Extrusion – Hard Alloy, Forging – Hard Alloy | Product qualification management for aerospace aluminum products | Global | 2001 – 2009 |
| Extrusion – Hard Alloy, Forging – Hard Alloy | Qualification management for advanced forged and extruded products | Global |
2009 – 2010
|
| Extrusion – Hard Alloy, Forging – Hard Alloy | Product qualification projects for forgings and extrusion: qualification of advanced alloy products for aerospace OEMs; transfer qualification for aero-derived alloys in automotive applications; Al-Li product qualification support | Global |
2013 – 2019
|
| Extrusion – Hard Alloy, Forging – Hard Alloys | Product qualification for automotive applications using aerospace-derived alloys: transfer qualification projects from aerospace to automotive structural components; alloy approval and testing support at OEM and Tier-1 level | Global | 2006 – 2019 |
| Qualification | Support of aerospace site and source qualification activities: coordination of customer audits, approval of new production sources, quality system alignment with Aerospace OEM / NADCAP and OEM-specific requirements across forging and extrusion plants | Global | 2001 – 2019 | Commercial Metal & Risk Management | Review metal risk management strategy & educate commercial departments in hedging of aluminium price and FX. | Central Europe | 2025 |
Project Development & Execution
| Rolling | Concept study “Potential Improvements of Adding a Finishing Stand to a Single Stand Hot Mill”, commissioned by a major rolling mill supplier | Southern Europe | 2020 |
| Remelting, Casting, Rolling and Finishing of Plate and Shate | FEED studies: strategy definition, drive process engineering, specify equipment, define plant layout and logistics, contribute to operational readiness planning | Middle East | 2024 – today |
| Remelting, Casting, Rolling and Finishing of Aluminium Rolled Products | Project study for an Aerospace Plate Rolling Mill Plant | Middle East |
2022
|
| Remelting, Casting, Rolling and Finishing of Aluminium Rolled Products | Project study “re-establish plate production” including periodical progress review | Europe | 2024 – 2025 |
| Remelting, Casting, Rolling and Finishing of Aluminium Rolled Products | Support of project development of a Green field Rolling Mill plant | North America |
2025 – 2026
|
| Business Development, Organizational Development | Create a site development master plan | Europe |
2013
|
| Product Development, Innovation, Qualification | Project lead: product development & qualification for major aerospace OEM; alloy application engineering for plate, sheet, extrusion and forging; qualification of innovative joining and forming technologies | Europe |
2001 – 2006
|
| Product Development, Innovation, Qualification | Aerospace OEM Advanced Metallic Initiative: alloy and product innovation program; development and qualification of advanced metallic materials to maintain competitiveness vs. CFRP | Global |
2001 – 2006
|
| Strategy, Investment, Technical Development, Qualification | Technical coordination and qualification for Al-Li casthouse investment ($100M): alloy qualification strategy, supply chain analysis, customer alignment for new Al-Li casting capability | Global | 2013 – 2019 |
| R&D | PhD research: deep drawability enhancement of aluminum sheet through process-optimized blanks; process development for lightweight sheet forming | Central Europe | 1996 – 2001 |
Operations Excellence & Readiness
| Remelting, Casting, Rolling and Finishing of Foil Products | Transformation project: from family towards corporate business organization, focus operations | Southern Europe | 2020 – 2023 |
| Remelting, Casting, Rolling and Finishing of Plate and Shate | Manage operations with focus on quality, reliability and maintenance improvement program with top-tier global consulting firm, revamping of cold-mill | Southern Europe | 2007 – 2009 |
| Cold Rolling, Finishing of Aluminium Rolled products | Implementation of a group-wide business system, introduction of Lean methods and tools, define, introduce and drive Performance Management System | Central Europe |
2009 – 2014
|
| Remelting, Casting, Rolling and Finishing | Lead debottlenecking of casting and preheating; Lead optimization projects: plate finishing and quality improvements in casting and rolling | Central Europe | 2014 – 2016 |
| Remelting, Casting, Rolling and Finishing | Develope Operational Readiness plan for Greenfield Rolling Mill plant | Middle East |
2010 – 2013
|
| Remelting, Casting, Rolling and Finishing | Misc. Projects in Restructuring, Business process improvements, Product development, | Europe / Middle East |
1988 – 2020
|
| Remelting, Casting, Rolling and Finishing | Introduce and maintain Lean manufacturing tools – 5S, TPM, Suggestion system, Daily Management, Kaizen | Europe / Middle East |
1993 – 2023
|
| Grinding Materials | WIP reduction | Europe |
1990
|
| Rolling | Implementation and start-up of ERP /MES / Production Scheduling System; Reorganization SC Department | Europe | 1994 |
| Rolling | Working Capital Optimization, reduction of40% | Europe | 1994 – 1995 |
| ERP Implementation, S&OP | Implementation and start-up of ERP / System; Reorganization Production scheduling | North America / Europe | 2001 – 2003 |
| Rolling | Supply Chain Optimization, paperless factory, working capital reduction, digitalization of the production processes | Europe | 2013 – 2020 |
| Rolling | Implementation of S&OP process, restructuring planning process | Europe | 2020 – 2021 |
| Rolling | Working Capital Optimization, reduction of40% | Europe | 1994 – 1995 |
| Rolling | Implementation of Kaizen / Continuous Improvement process, set up of a Kaizen organization | Europe | 1994 – 1995 |
| Components Manufacturing | Implementation of Kaizen / Continuous Improvement process, set up of a Kaizen organization | Europe | 2001 – 2003 |
| Rolling | Commissioning and start-up of two new rolling mills | Europe | 2014 – 2021 |
| Casting, Extrusion | New Product Development | Europe | 2025 – 2026 |
Recycling & Sustainability
| Remelting, Casting | Prepare plan for Operational Readiness for a Greenfield remelting/casting plant. | North America | 2024 |
| Remelting, Casting | Project development and Operational readiness plan for Greenfield remelting and billet casting plant. (Phase 1). Extend Remelting & Homogenization Capacity (Phase 2) | North America | 2023 – 2026 |
| Scrap trader | Project study for remelting and slab casting plant | North America | 2022 |
| Remelting, Casting | Review of Scrap remelting capabilities and develop plan to increase absorption of conatminated scrap | Europe | 2025 – 2026 |
| Remelting, Casting, Rolling and Finishing | Establish and start up of a remelting and casting facility in a „brown field“ plant | Southern Europe | 2018 – 2019 |
| CBAM | CBAM compliance consulting: embedded emissions analysis for aluminum producers; CBAM reporting methodology for aluminium products; secondary material benchmarking | Global | 2023 – today |
Technology, Innovation & Digitalisation
| R&D | Project lead of aerospace R&D portfolio valuations | Central Europe | 2018 – 2019 |
| Digtial Transformation | Program lead of global CRM implementation. Strategy, vendor selection, design, implementation, post go-live change management and maintenance | Global | 2020 – 2022 |
| ERP Implementation, S&OP | Program lead of global S&OP transformation journey. Including digital transformation initiatives. Strategy development, vendor negotations and selection | Global | 2023 – 2024 |
| Data Management | Program lead of data warehouse migration strategy | Global | 2023 – 2024 |
| ERP Implementation, S&OP | Business lead of global SAP S/4HANA smart field implementation | North America / Europe | 2024 – 2025 |
| Digtial Transformation | Digital Material Passport development and deployment for aerospace and automotive; digital replacement of paper certificates (CoC / EN 10168 / 3.1), data space development project led by Aerospace OEM and 30 project partners | Global | 2024 – today |
| Product Development, Innovation, Qualification | Materials consulting & aluminium application engineering for Aerospace OEM; alloy selection and development for plate, sheet, extrusion and forging products; technical interface between Aerospace OEM design and aluminium product R&D and manufacturing sites | Global | 2001 – 2006 |
| Product Development, Innovation, Qualification | Alloy transfer and product development for forgings and extrusions; selection and adaptation of aerospace high-performance alloys (2xxx, 7xxx) for automotive structural applications; technical support for Al-Li product introduction | Global | 2013 – today |
We are happy to provide more information on request. Our projects typically start with a focused discussion to understand your situation, priorities and potential impact.
Case Studies
Commercial and Investment Strategy for a Rolling Mill
Challenge: Lack of strategic clarity on target markets, product segments and future investment priorities in a competitive rolling market.
Focus Areas: Commercial Strategy · Market Segmentation · Investment Roadmap
Outcome: Aligned commercial and investment strategy with clear market focus and prioritized CAPEX decisions.
Restructuring an Extrusion Business to Restore Profitability
Challenge: An underperforming extrusion business facing declining margins, complex product portfolio and operational inefficiencies.
Focus Areas: Restructuring · Operations Excellence · Portfolio & Cost Optimization
Outcome: Comprehensive turnaround program stabilizing operations and creating a clear path back to profitability.
New Plant Layout and Machinery Concept for Aerospace Machining
Challenge: Need for a future-proof plant layout and machinery concept to improve flow, efficiency and competitiveness in aerospace machining.
Focus Areas: Plant Layout · Machinery Concept · Operational Readiness · Automation
Outcome: Integrated layout and machinery concept optimized for process flow, scalability and performance.
Our case studies are closely linked to our service portfolio and reflect the typical challenges we address across the downstream value chain.
Ready to strengthen performance, reduce complexity and unlock growth?
Address
Lightmet Consulting FlexCo
Konstantingasse 6-8/9
1160 Vienna
Austria