Operational Excellence for the Manufacturing Sector

Practical and efficient methods to maximize operational cost-efficiency

Performance Improvement for Manufacturing Companies

Manufacturing processes can be significantly optimized through smart design and the strategic integration of digital technologies. This leads to a significant increase in productivity while simultaneously reducing labor costs.

Ultimately, streamlined workflows form the foundation for sustainable growth and long-term profitability.

Key Objectives of Operational Performance Improvement

Increased Production Output

Establishing transparency across the production process is essential for increasing output. Measuring Overall Equipment Effectiveness (OEE) allows businesses to quantify the impact of improvement measures and ultimately boost output.

Reduced Production Costs

To remain competitive globally, continuous production optimization is critical. Cost savings can be achieved through targeted investments in automation and by eliminating non-value-adding activities.

Improved Delivery Performance

Enhancing delivery capabilities requires optimizing the supply chain, establishing service level agreements (SLAs) with partners, and maintaining open communication with suppliers, ultimately leading to shorter delivery times.

Minimized Capital Commitment

Inventory held in warehouses or stores often ties up significant working capital. Adjusting order quantities and lead times, combined with inventory optimization initiatives, can free up capital and improve operational efficiency.

Minimized Capital Commitment

Inventory held in warehouses or stores often ties up significant working capital. Adjusting order quantities and lead times, combined with inventory optimization initiatives, can free up capital and improve operational efficiency.

Minimized Capital Commitment

Inventory held in warehouses or stores often ties up significant working capital. Adjusting order quantities and lead times, combined with inventory optimization initiatives, can free up capital and improve operational efficiency.

Optimized Setup Times

We apply SMEDs (Single-Minute Exchange of Dies) to reduce setup times sustainably, which enables efficient handling of smaller order sizes.

Reduced Lead Times

Large work-in-progress (WIP) orders and inefficient communication between departments often cause longer lead times.

Enhanced Quality

Quality improvements are achieved through Six Sigma analyses and quality checkpoints throughout the production process.

Increased Equipment Availability

Frequent minor disruptions and unplanned downtime disturbances affect the production flow. Documenting these issues allows businesses to identify common causes for disruptions using tools like the “5 Whys”.

Advanced Automation Levels

Due to ongoing technological advancements, it is now possible to automate even the most complex production processes. Automated systems offer consistent quality and reduced reliance on manual labor.

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Relevant Questions Regarding Process Optimization

Relevant Questions Regarding Process Optimization

We help businesses develop strategies and implement solutions to optimize processes and facilitate potential ownership transitions.

What factors are preventing us from reaching our planned production volumes?

Do we have visibility into constraint machines for each production program?

What strategies can we implement to relieve bottlenecks or increase capacity?

Is it efficient to produce items that subsequently accumulate before a constrained process step?

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

Are we measuring material consumption in a transparent manner?

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

Systems

Why is there such a high volume of semi-finished goods on the production floor, and why are our warehouses overstocked?

How long does raw material remain in storage before it enters production?

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?

Are we producing in optimal lot sizes?

Are we measuring material consumption in a transparent manner?

Do our customers require the full order quantity at once? Or could we deliver smaller quantities?

Materials

Responsibility for malfunctions and machines is not known?

Do we have clarity on which employees are experts for specific machines?

Why are rush orders only processed during the day shift?

Why do we keep a fixed shift model despite fluctuating demand, for example, no night shifts during peak periods?

Are we systematically investing in employee upskilling and training?

Are our employees motivated? How can we enhance their engagement further?

Do employees spend excessive time searching for tools or materials?

Staff

Why are our machines running slower than the manufacturer announced?

Why do we set up machines for an entire shift? Are these durations justifiable?

Have we analyzed and documented our setup processes to enable future improvements?

Could setup times be significantly reduced by utilizing modular system designs or better setup components?

Why do our machines frequently experience breakdowns? Could we have prevented the downtime by precautionary exchanging components?

Why do we run machinery until failure instead of conducting maintenance regularly? Does this impact product quality?

Machinery

Why are deviations from specifications only detected during final quality control?

Why do we repeatedly have the same quality issues?

How do we verify whether a machine has been correctly set up?

Are we measuring every individual part or only sampling a few parts per unit?

Under which circumstances should we measure additional parts of the machinery?

Are our measurement instruments capable of assessing the specifications we aim to achieve?

Quality

Common Project Schedule

Typically, our projects aimed at achieving operational excellence are divided into three sequential, self-contained phases.

Analysis

We explore the dynamics of your company, gaining insight into your ambitions and challenges. Then, we develop a range of potential actions and strategies, preferably in collaboration with your team of employees.

Validation

The proposed strategies are prioritized based on expected impact, cost, and feasibility. The availability of internal resources is a key consideration when implementing the suggested measures effectively.

Implementation

We assist you during the implementation process and put the selected strategies into practice in collaboration with you. Our approach emphasizes pragmatic solutions to achieve quick results and increase operational efficiency.

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