The ~39,600-strong global workforce — capacity utilization, right-first-time and skilling by cluster, and the capacity already paid for but sitting idle.
The workforce runs at 86% capacity utilization vs a 93% target — 7 points of already-paid capacity sitting idle, worth ~€652 M of throughput with zero new lines. The idle capacity is concentrated where automation and skilling are still ramping; closing it converts straight to margin.
3 of 3 headline metrics improving vs prior · still off target: Plant Capacity Utilization 85.0% vs 90.0%, On-Time Delivery (OTIF) 96.0% vs 98.0%
Rest of World (MEA · South America) runs lowest at 80% utilization with 140 open reqs and 82% skilled — the thinnest bench and the biggest idle slice.
~7 points of idle, already-paid capacity across 39,600 people — running it adds ~€652 M of throughput with no new lines.
The workforce is a largely fixed cost whether or not the lines run full. At 86% capacity utilization vs a 93% target, several points of already-paid capacity sit idle — the single biggest operational lever after pricing, and it's concentrated where plant automation (SAP/PLM) and skilling are still ramping.
Capacity utilization, right-first-time and skilling by cluster — the watch clusters match the transformation map.
| Cluster | Headcount | Capacity util | Right-first-time | MTTR | Skilled | Open reqs |
|---|---|---|---|---|---|---|
| Europe — Manufacturing & Ops | 15,000 | 85% | 98% | 5.4h | 88% | 420 |
| North & Central America | 9,000 | 88% | 97% | 5h | 86% | 520 |
| Asia-Pacific (India · China) | 8,000 | 86% | 96% | 5.8h | 84% | 380 |
| Corporate / R&D / Digital | 3,000 | 87% | 99% | — | 92% | 180 |
| Rest of World (MEA · South America) | 2,600 | 80% | 95% | 6.2h | 82% | 140 |
| Sales / Marketing / Channel | 2,000 | 86% | 97% | — | 90% | 90 |
Running the idle capacity adds throughput with zero new lines.
~7 points of idle, already-paid capacity across 39,600 people. Closing it — better line balancing, less rework, and faster skilling onto automated lines — converts straight to margin. Pair with right-first-time (97%→99%): every avoided rework lot is pure profit.
Same clusters where automation & skilling programs are still ramping.
Not a coincidence: Rest of World (MEA · South America) and Europe — Manufacturing & Ops run lowest — the same clusters where plant automation (SAP/PLM) and skilling are still ramping. Accelerating skilling and line balancing lifts utilization and right-first-time together.