“The biggest win was gaining full control over quality and timelines while expanding what we can deliver.”

Management Team, NIKI Ltd.

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PROJECT SNAPSHOT

Project

End-to-end modernization of NIKI production facilities

Location

Bulgaria

NIKI Role

Owner and executor of the full upgrade program

Scope

New metalworking machinery, dedicated woodworking facility via Lignater Ltd., integrated software, in-house quality control, workforce training

Timeline

Planning > procurement > integration > training > Lignater Ltd. launch (2024)

Materials

Metal, wood, composites, engineered finishes

THE CHALLENGE

Production capacity under pressure

Growing project complexity and rising client expectations increased demand on quality, speed, and delivery control.

Outsourced production made consistency harder to protect across batches, and it pushed feedback later in the process, when timelines were already tight. Coordinating wood and metal execution across separate parties also increased the risk of misalignment in fit, finish, and final assembly.

As projects became more technically demanding, the gap between what external manufacturing could reliably deliver and what clients required widened. NIKI needed production ownership that could be enforced daily, not negotiated project by project.

Key constraints

Maintaining uninterrupted production throughout the upgrade

Significant capital investment in machinery and facilities

Building team competence in parallel with operational expansion

THE SOLUTION

Full in-house production, introduced without stopping active work

NIKI management defined long-term capacity goals and committed to bringing every critical production step in-house. The program was sequenced to protect delivery continuity, bringing new capability online progressively while workflows, quality standards, and training were introduced in parallel.

What was delivered

New-generation metalworking machinery to support more precise, repeatable output

Dedicated woodworking facility launched through Lignater Ltd. in 2024 to handle higher build complexity

Integrated production and management software to improve job visibility, handoffs, and accountability

In-house quality control implemented across departments, with checkpoints built into the workflow

Optimized production layouts to reduce unnecessary handling and improve flow

Structured workforce training aligned to each phase of ramp-up, so standards were adopted with confidence

“NIKI stood out because we invested in long-term capacity, not short-term fixes.”

Operations Director, NIKI Ltd.

Key decisions

Metal and wood production were kept under one operational structure to reinforce integration and maintain a single point of control for mixed-material projects.

New machinery was brought online progressively, with team training sequenced to match each stage.

Quality standards were introduced early, with defined checkpoints, so they became part of daily execution rather than a corrective step later.

THE RESULT

Higher consistency, faster execution, fewer external handoffs

The modernization program improved quality consistency, reduced execution friction, and strengthened production control across complex builds.

With wood and metal work coordinated internally, NIKI can manage quality and timelines through daily standards and clearer operational visibility, rather than relying on external alignment to achieve predictable outcomes.

Business impact

Higher and more consistent quality across metal and wood output

Faster execution of complex projects with fewer revision cycles

Expanded production range across materials and component types

Stronger control over timelines and costs

Reduced reliance on outsourcing for critical production steps

“What surprised us most was how quickly productivity and quality improved once the new systems were live.”

Production Manager, NIKI Ltd.

The launch of Lignater Ltd. in 2024 marked the most significant milestone: a dedicated woodworking facility built to handle the technical complexity that current client projects demand.

WHY NIKI LTD.

End-to-end control, under one roof

The investment was made in direct response to what complex projects require: consistent quality, delivery control, and the technical capacity to adapt without losing execution momentum.

The upgraded production setup is now the default way NIKI delivers client work, supported by modern machinery, integrated workflows, and quality standards enforced across teams.

Clients working with NIKI benefit from:

Metal and wood production under one roof, with fewer external handoffs

In-house quality control integrated from design through delivery

A production team built for increasing project complexity

Direct accountability from brief through final delivery

Continued investment in people, machinery, and process

NIKI selected this path because consistent delivery at the level clients require depends on owning the process. The production infrastructure built through this program is the foundation every client project now runs on.

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