Shopfloor Management

• Optimisation of existing processes / material flows, including consideration of future performance requirements
• Increasing efficiency and flexibility in production
• Improvement of key figures such as LT, OEE etc. while minimising costs at the same time

• A potential analysis is the first step in an optimisation project
• Process and value stream mapping and data analyses to estimate potentials
• Evaluation of your current processes and structures in terms of process and resource efficiency
• Development of the target status together with the process owners, including a check for consistency and feasibility
• Preselection, comparison, evaluation and recommendation of suitable material flow technologies

• the organisational structure and the factory layout
• the established processes, e.g. production planning and control, production supply and disposal
• the material flow
• the key production indicators, e.g. work in progress, lead time and adherence to delivery dates, etc.
• an objective and reliable final evaluation

• Summary of the identified weaknesses with their causes, a clustering and the identification of core problems
• Basis for decision-making with specific recommendations for action, including interdependencies and priorities
• Help to remove the ‘blinkers’
• Analysis of the entire value chain
• Trigger for a change process

• Analysis and optimisation of internal order management
• Consideration of existing and future requirements for the production system
• Material flow orientation in the supply and disposal processes
• Shifting production preparation processes to logistics
• Expansion into a holistic production supply concept through standardised processes and container concepts for each supply class
• Consideration of lean principles along the entire process

• Efficient processes for demand- and consumption-orientated supply and disposal in production
• Definition of responsibilities at the interface between production and logistics
• Efficient design of the transfer areas for production supply and disposal
• Reduction of stock levels through demand-orientated supply to production
• Optimised configuration in the area of conflict between staging area requirements and reliable production supply

• Holistic design of the workstation system, taking into account the existing and future requirements of your production system
• Structuring the layout and standardising the workstations
• Innovative solutions for optimum support for your employees at the workplace
• Examination of the necessary systemic networking of your workstations

• Increase your process efficiency and reduce lead time through flow-orientation in the process
• Creating a scalable workplace system that can be adapted to your needs and the needs of your customers

This is how we analyse your production system ‘holistically’:

• Allocation of products to the systems and their flow-orientated arrangement in the layout
• Production sequences and the resulting stock levels
• Lead time
• Capacity utilization rates and batch sizes
• Proven process model with a new level of efficiency and quality

Operational Excellence (OPEX)

We offer companies an innovative and customised approach to evaluating and optimising production processes.

The special challenges for an optimisation project in the process industry are realised using a specially developed toolset based on lean management methods. 

• Teaching the theoretical basics of lean production and instructing the participants
• Three rounds of games within the fictive factory, each followed by a group discussion
• Optimisation approaches are not predetermined, but developed independently
• Concluding discussion and transfer of the content to the participants' own production conditions

• Interactive communication of the objective of lean production principles
• Reducing reservations through active discussion with the experienced trainers from Fraunhofer IML
• Developing and experiencing lean production design approaches such as one-piece flow, kanban or cycle equalisation
• Increasing the commitment of participants for upcoming lean projects