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
| 2025 | Remelting, casting, rolling and finishing of Aerospace Plate and Shate | Development of go-to-market strategy, sourcing strategy, pitch-deck development, sales support, pricing strategy and benchmarking | Saudi Arabia |
| 2024 | Aluminium rolling | Development of a commercial strategy, including an investment program; optimization of product mix | Europe |
| 2024 | Rolling incl. remelting and casting | Support of M&A preparation. Definition of improvement potential in marketing, sales, product mix, operational performance and potential cooperations | Central Europe |
| 2022-2023 | Components manufacturing / machining | Development of a corporate strategy including an investment program; elaboration of an asset development concept and implementation plan | Europe |
| 2021-2023 | Aluminium rolling | Development of a new corporate strategy and supervising implementation as head of the PMO | Europe |
| 2022-2023 | Automotive supplier (Tier 1, 2) | Temporary replacement of the CEO until a successor was appointed | Germany |
| 2022 | Foil rolling incl. remelting and casting | Due diligence including assessment of organization, assets, capabilities, CAPEX and business plan; identification of improvement potential | Italy |
| 2021-2022 | Casting – sand- casting | SME in sale of sand-casting business unit and site. Supported investment banks with market intelligence and CIM development, among others | France |
| 2021-2022 | Rolling, painting (post processes) | Project lead in strategic partnership negotiations with a lacquer and paint supplier concerning new supply and manufacturing agreements | France / Germany |
| 2021-2022 | Aerospace components manufacturing / machining | Project leader for post-merger integration | Europe |
| 2021 | Aerospace components manufacturing / machining | Responsible for the strategy process of an acquisition of a German aerospace machining company | Europe |
| 2021 | Rolling incl. remelting and casting | Due diligence including assessment of organization, assets, capabilities, CAPEX and business plan; identification of improvement potential | Several locations in in West- and North Europe |
| 2021 | Rolling incl. remelting and casting | Due diligence including assessment of organization, assets, capabilities, CAPEX and business plan; identification of improvement potential | Italy |
| 2020 | Remelting, casting, rolling and finishing | Technical due diligence to support the acquisition of a European integrated aluminium rolling mill by private equity (operational excellence / equipment / EHS) | Europe |
| 2019-2020 | Remelting, casting, rolling and finishing of Aerospace Plate and Shate | Support feasibility study “Special Metals Cluster” in the framework of the Saudi “Vision 2030”, with a major international consulting firm | Middle East |
| 2000-2020 | Misc. rolling companies, incl. remelting and casting | Due diligence including assessment of organization, assets, capabilities, CAPEX and business plan; identification of improvement potential | Poland, Belgium, Russia, Germany |
| 2018-2019 | Casting – large billets | Co-program lead of strategic investment (CAPEX) project in large billet capability. | France |
| 2017–2019 | Remelting, casting, rolling and finishing of Plate and Shate | Manage carve-out from an international group, creation of a competitive stand-alone structure in a private equity context, strategy process and turn-around management | Italy |
| 2013-2014 | Rolling incl. remelting and casting | Establish, start-up Greenfield plant & manage temporary operation as Operation Director | Middle East |
| 2013 | Hard alloy extrusion | Project lead for the attempted acquisition of an Italian extrusion company | Europe |
| 2011-2012 | Hard alloy extrusions | Managing Director with full P&L responsibility (€50M); execution of €12M investment program; restructuring and stabilization of the organization |
Italy
|
| 2010-2011 | Hard alloy extrusions | Commercial Director: development of product and sales strategy; establishment of dedicated sales and inside sales teams |
Italy
|
| 2005-2009 | Hard alloy extrusion | Elaborate and execute a commercial strategy and product mix optimization | Europe / Asia / Russia |
| 2005-2007 | Rolling, extrusion and forging incl. remelting and casting | Led integration of a newly acquired large scale organization into a US company. Temporary management as Executive Director Operations | Russia |
| 2004-2005 | Aluminium rolling | Restructuring / revamping of an aluminium rolling mill, execution of a massive investment program | Europe |
| 2001-2004 | Components manufacturing / machining | Start-up and development of several companies, elaboration of corporate strategies, site development concepts and layout | Europe |
| 2001 | Aerospace components | Interims Managing Director | USA |
| 2000-2001 | Medical engineering | Project lead for the acquisition of a 40% stake at a medical engineering company | Europe |
| 1999–2007 | Remelting, casting, rolling and finishing of aluminium rolled products | Integration of a plant after acquisition, different improvement projects for production and maintenance, drive and manage a major investment program throughout the plant | Italy |
| 1998-1999 | Hard alloy extrusions | Development of a corporate strategy and restructuring plan, cost cutting measures | Europe |
Sales & Business Development
| 1995-2022 | Aluminium rolling, extrusion, several different metal components companies | Developing new sales channels, optimizing product mix, establishing product management teams, developing and expanding business volume, restructuring sales teams, increase product focus | Europe / USA / Asia |
| 2017-2020 | Market intelligence | Aerospace market intelligence lead / SME | Global |
| 2019 | Advanced aluminium alloys (Aerospace / Automotive / Industrial) | Business Development Manager Advanced Alloys: alloy product development and qualification; transfer of aerospace alloys to automotive and industrial applications; market and technology review |
Europe / Global
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| 2019 | Casting – sand casting | Project lead in developing growth strategy for aerospace sand casting products and business unit | France |
| 2013-2019 | Forgings & extrusions (Aerospace / Automotive) | Business Development Manager: product development and qualification of forged and extruded products; transfer of aerospace alloys to automotive applications; technical support for Al-Li casthouse investment ($100M) |
Europe / Global
|
| 2013-2019 | Aerospace / Automotive – Forgings, Extrusions, Al-Li products | Product qualification projects for forged and extruded components; qualification of advanced alloys for aerospace OEMs; transfer qualification of aerospace-derived alloys for automotive applications; Al-Li product qualification support |
Europe / Global
|
| 2006-2019 | Automotive – Hard alloy extrusions and forgings | 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 |
Europe / Global
|
| 2001-2019 | Aerospace – Producer / site qualification | Support of aerospace site and source qualification activities: coordination of customer audits; approval of new production sources; alignment of quality systems with aerospace OEM and NADCAP requirements across forging and extrusion plants |
Europe / Global
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| 2018 | Airware (Al-Li) | Driving Airware (Al-Li) business development outside aerospace | Global |
| 2017-2018 | Casting, rolling, cold rolling and finishing | Project lead in developing growth strategy for aerospace sheet | France |
| 2017-2018 | Extrusions (hard alloys) | Project lead in developing growth strategy for aerospace extrusions | France |
| 2017 | Casting – Airware (Al-Li) | Airware casting capacity review. Pre-study for casting capacity expansion options | France |
| 2009-2012 | GRP pipes | Growing and developing sales network in Asia | Europe / Asia |
| 2009-2010 | Aerospace forgings & extrusions (Airbus account) | Global Account Manager for aerospace OEM: management of qualification programs for advanced forged and extruded products; negotiation of long-term agreements; development of new alloy business | Global |
| 2009-2010 | Aerospace – Forgings & extrusions | Qualification management for advanced forged and extruded products |
Europe / Global
|
| 2008-2009 | Aluminium rolling | Developing export organization, growing sales volume | Europe / Asia |
| 2006-2009 | Hard alloy extrusions (Aerospace / Automotive / Oil & Gas / Defense) | Application engineering and business development: alloy and product qualification across multiple industries; development of hard alloy extrusion products; implementation in new markets |
Europe / Russia / Asia
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| 2001-2009 | Aerospace – Plate, Sheet, Extrusion, Forging | Management of qualification programs for aerospace aluminium products |
Europe / Global
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| 2006-2008 | Hard alloy extrusions | Implementation of business development organization. Creating “Growth Funnel” for new products, market implementation | Europe / Russia / Asia |
| 1995-1998 | Aluminium rolling | Starting and developing sales organization in Japan for the Asia Pacific region | Asia Pacific |
Project Development & Execution
| 2025-2026 | Rolling incl. remelting and Casting | Support of project development of a Greenfield Rolling Mill plant | North America |
| 2024–2026 | Remelting, casting, rolling and finishing of Aerospace Plate and Shate | Support FEED 2 and 3 studies: support strategy definition, drive process engineering, specify equipment, define plant layout / intraplant logistics, contribute to operational readiness planning | Middle East |
| 2024-2025 | Rolling incl. remelting and Casting | Project study “re-establish plate production” incl. progress review | Europe |
| 2022 | Rolling incl. remelting and casting | Project study for an Aerospace Plate rolling mill plant | Middle East |
| 2020 | Hot rolling | concept study “Potential Improvements of Adding a Finishing Stand to a Single Stand HM”, commissioned by a major rolling mill supplier: productivity / quality / capabilities | Italy |
| 2013-2019 | Aluminium-Lithium alloys (casthouse investment) | Technical coordination and qualification for Al-Li casthouse investment ($100M): development of alloy qualification strategy; supply chain analysis; customer alignment for new Al-Li casting capability | Europe / Global |
| 2013 | Aluminium location with several companies | Create a site development master plan | Europe |
| 2001-2006 | Aerospace aluminium products – plate, sheet, extrusion, forging | Aerospace Project Manager: product development and qualification for major Airbus programs (A380, A400M, A350, A318); alloy application engineering; qualification of innovative joining and forming technologies | Europe (Switzerland) |
| 2001-2006 | Aerospace structural materials (metallic) | Aerospace OEM Advanced Metallic Initiative: alloy and product innovation program; development and qualification of advanced metallic materials to maintain competitiveness versus CFRP | Europe / Global |
| 1996-2001 | Lightweight aluminium sheet – deep drawing research | PhD research: improvement of deep drawability of aluminium sheet through process-optimized blanks; development of processes for lightweight sheet forming | Germany (Erlangen) |
Operations Excellence & Readiness
| 2020–2023 | Remelting, casting, rolling and finishing of Foil products | Drive transformation in operations, from family business towards a structure according to industry best-practice, quality and productivity improvements, support major investments | Italy |
| 1993-2023 | Rolling incl. remelting and casting | Introduce and maintain lean manufacturing tools – 5S, TPM, suggestion system, daily management, Kaizen | Several locations in Europe and Middle East |
| 2020-2021 | Aluminium rolling | Implementation of S&OP process, restructuring planning process | Europe |
| 2014-2021 | Aluminium rolling | Commissioning and start-up of two new rolling mills | Europe |
| 2013-2020 | Aluminium rolling | Supply chain optimization, paperless factory, working capital reduction, digitalization of the production processes | Europe |
| 1988-2020 | Rolling incl. remelting and casting | Misc. projects in restructuring, business process improvements, product development | Several locations in Europe and Middle East |
| 2014–2016 | Melting, casting, rolling and finishing of Aerospace Materials |
Lead debottlenecking of casting and preheating, diverse optimization projects in hot rolling and plate finishing, quality related improvements in hot rolling and casting, preparation of investment proposals | Germany |
| 2009–2014 | Cold rolling and finishing of aluminium rolled products for Foil, Litho, Can + Automotive markets | Implementation of a group-wide business system, introduction of lean methods and tools, define, introduce and drive performance management system of the groups pilot plant | Germany / Europe |
| 2010-2013 | Rolling incl. remelting and casting | Develop operational readiness plan for Greenfield rolling mill plant | Middle East |
| 2007–2009 | Remelting, casting, rolling and finishing of Plate and Shate | Management of operations with focus quality and reliability (availability), maintenance improvement program with global consulting firm, revamping of cold-mill, introduction of a business system | Italy |
| 2001-2003 | Aerospace components manufacturing | Implementation and start-up of ERP system; reorganization production scheduling | USA / Europe |
| 2001 -2003 | Components manufacturing | Implementation of Kaizen / continuous improvement process, set up of a Kaizen organization | Europe |
| 1994-1995 | Aluminium rolling | Implementation of Kaizen / continuous improvement process, set up of a Kaizen organization | Europe |
| 1994-1995 | Aluminium rolling | Working capital optimization, reduction of 40% | Europe |
| 1994 | Aluminium rolling | Implementation and start-up of ERP /MES / production scheduling system; reorganization SC department | Europe |
| 1990 | Grinding materials | WIP reduction | Europe |
Recycling & Sustainability
| 2023-today | Aerospace & industrial aluminium supply chain (CBAM compliance) | CBAM compliance consulting: analysis of embedded emissions for aluminium producers; development of CBAM reporting methodology; benchmarking of secondary material flows |
Europe / Global
|
| 2025-2026 | Remelting and casting | Review of scrap remelting capabilities and develop plan to increase absorption of contaminated scrap | Europe |
| 2023-2026 | Remelting company | Project development and operational readiness plan for Greenfield remelting and billet casting plan (Phase 1); Extend remelting and homogenization capacity (Phase 2) | USA |
| 2024 | Remelting facility | Prepare plan for operational readiness for a Greenfield remelting / casting plant | USA |
| 2022 | Scrap trader | Project study for remelting and slab casting plant | USA |
| 2018-2019 | Rolling inc. remelting and casting | Establish and start-up of a remelting and casting facility in a „brown field“ plant | Spain |
Technology, Innovation & Digitalisation
| 2024-today | Digital Material Passports (DMP) – Aerospace and Automotive | Development and deployment of Digital Material Passports: digital replacement of paper certificates (CoC / EN 10168 / 3.1); participation in data-space development project led by aerospace OEM and more than 30 partners | Europe / Global |
| 2013-today | Aerospace & Automotive – Advanced aluminium alloys (2xxx, 7xxx, Al-Li) | Alloy transfer and product development for forgings and extrusions: adaptation of aerospace high-performance alloys for automotive structural applications; technical support for Al-Li product introduction | Europe / Global |
| 2024-2025 | ERP | Lead of global SAP S/4HANA smart field implementation, including four aluminium sites, one R&D center, three corporate offices | USA, Czech Republic, France, Switzerland |
| 2023-2024 | S&OP and IBP | Program Lead of global S&OP transformation journey including digital transformation initiatives. Strategy development, vendor negotiations and selection | Global |
| 2023-2024 | Commercial data lake | Program Lead of commercial data lake data migration strategy | Global |
| 2020-2022 | CRM | Program lead of full Salesforce implementation. Strategy development, vendor negotiations and selection, design and implementation as well as all post go-live change management processes and maintenance. | Global |
| 2018-2019 | R&D | Project Lead of the Aerospace R&D Portfolio Valuations | France |
| 2001-2006 | Aerospace – Plate, Sheet, Extrusion, Forging (2xxx, 7xxx, Al-Li) | Materials consulting and aluminium application engineering for aerospace OEM: alloy selection and development; technical interface between OEM design teams, aluminium R&D and manufacturing sites | Europe / Global |
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