Operational performance for production

Simple and quick measures to realize potential savings

Increased performance in the Production

Processes in the manufacturing industry can be made faster, simpler and more efficient through clever design and the use of digital technologies. On the one hand, this makes it possible to operate with fewer staff and, on the other, to significantly increase productivity.

Ultimately, optimized processes form the basis for profitable business and sustainable growth.

Typical goals of operational performance improvement

Here we have far too many points in the PPT (also compared to craftsmanship). Can this also be reduced to 3-6 points and summarized?

Increase output

In order to sustainably increase output, it helps to establish transparency within the production process. By measuring the OEE (Overall Equipment Effectiveness), the influence of further measures is determined and the output quantity is increased

Reduce production costs

Constant optimization of production is necessary in order to survive international competition in the long term. Potential can be leveraged through larger projects such as investments in automation or the consistent identification and avoidance of processes that do not add value

Improve delivery capability

By optimizing the supply chain, service level agreements with partners, open communication with suppliers, etc., the company's own ability to deliver and at the same time its own delivery time can be shortened

Reduce capital commitment

Stocks in the warehouse and on the shop floor often tie up considerable capital. Coordinating order sizes and procurement times can reduce stock levels. Inventory optimization of the warehouse can also be useful

Reduce capital commitment

Stocks in the warehouse and on the shop floor often tie up considerable capital. Coordinating order sizes and procurement times can reduce stock levels. Inventory optimization of the warehouse can also be useful

Reduce capital commitment

Stocks in the warehouse and on the shop floor often tie up considerable capital. Coordinating order sizes and procurement times can reduce stock levels. Inventory optimization of the warehouse can also be useful

Setup time optimization

We use SMED to sustainably reduce set-up times and thus enable the efficient processing of smaller batch sizes

Reduce throughput times

Common reasons for longer lead times are large active order backlogs (WIP) and temporary storage, as well as communication inefficiencies between departments

Increase quality

Six Sigma analyses and quality measuring stations in the product development process enable quality deviations to be identified and reduced in good time. This typically also reduces rejects

Increase system availability

Many smaller system stops and production interruptions often prevent a smooth process. Documenting the causes helps to identify the most common faults and rectify them using the 5 Why method

Increase degree of automation

Advances in development mean that even more complex production processes can now be partially or even fully automated. Automated processes often run more stably, without manual work and deliver consistently high quality

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Relevant questions for production optimization

Relevant questions for production optimization

We support companies from the development and implementation of growth strategies to the optimization of processes and the possible sale of the company.

Why are we not achieving the planned quantities?

Do we know our bottleneck machines for each production program?

How can we relieve bottlenecks or increase capacity?

Does it make sense to produce products that are then left in front of a bottleneck?

Why do our parts take days to reach the final inspection, although the machine time is only a few hours?

Do we measure our production performance? Is this visible to everyone at all times?

Do we need all that paper in production or can it also be done digitally?

Systems

Why are there so many semi-finished products on the production floor and why are our warehouses full?

How long does our raw material stay in the warehouse before it is actually needed?

Why are we spending money on warehouse expansion instead of faster facilities?

How many finished goods that are currently in stock can we still sell on the market?

Do we manufacture in the right batch sizes?

Do we measure our production performance? Is this visible to everyone at all times?

Do our customers need the entire order quantity immediately? Or can we deliver in smaller quantities?

Material

Responsibility for malfunctions and machines is not known?

Are we aware of which employees are experts on which machines?

Why are rush jobs only carried out during the day shift?

Why do we have fluctuating order situations but a fixed shift model, e.g. no night shift?

Do we regularly ensure that our employees receive further training and acquire new skills?

Are our employees motivated? How could we further increase motivation?

Do our employees spend a lot of time searching for tools, materials, etc.?

Employees

Why are our machines running slower than the manufacturer announced?

Why do we set up machines over an entire shift? Doesn't that take far too long?

Have we analyzed and documented our setup processes in order to shorten them?

Can we make set-up times significantly faster by using modular systems and improving set-up components?

Why do our machines often break down? Couldn't the affected parts have been replaced before the machine breaks down?

Why do we run our machines until the next breakdown without carrying out maintenance work first? Does this also affect quality?

Machines

Why is it only during the final goods inspection that products are out of specification?

Why do we regularly make the same mistakes?

How do we determine whether a machine is set up and adjusted correctly?

Do we measure each part individually or just a few from each batch?

When should additional parts be measured in the measuring room?

Are our measuring instruments capable of measuring the specifications we want to achieve?

Quality

Typical project process

As standard, our projects to improve operational performance are divided into three consecutive and self-contained phases.

Analysis

We get to know your company and understand your ambitions and challenges. We then work with you to draw up a catalog of options and measures. Ideally, this is done together with a team from your workforce.

Validation

The options and measures are prioritized. The expected impact, costs and feasibility are taken into account. The availability of internal resources required to implement the measures is also an important factor.

Implementation

We support you with the implementation and realize solutions together. We work with pragmatic solutions to achieve results quickly and increase operational efficiency.

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Contact us, we look forward to getting to know you and mastering exciting challenges together.

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