- Mechanical engineering
Optimization of production areas is our core competence. However, production must always be seen as part of a corporate organism which must be connected via many interfaces with other essential areas in the company, such as development, purchasing, controlling and human resources. Achieving an optimum in production therefore also requires a comparison of objectives and processes with adjacent areas.
This project example describes a project assignment in which we were allowed to reach far into the adjacent areas, right across the interfaces from and to production responsibility, in order to identify optimization potential for the entire company processes.
After we had been able to support a manufacturing company over several years in the process of equipping the production areas with the latest plant technology, an innovative planning system and in the reorganization of organizational responsibilities, the performance limits in production were obvious to us and we successively identified the potentials with the company and transferred them into suitable measures. Starting from the core process of value creation in production, it was possible to achieve significant improvements in the company’s results by adapting processes and rules right through to sales.
Profile
Company size
Location
Germany
Period
1.5 years
Branch
- Mechanical engineering
Percentage of individual services
- reactive situation stabilization
- holistic concept development
- risk analysis production performance
- Reaktive Situationsstabilisierung
- Ganzheitliche Konzepterstellung
- Risikoanalyse Produktionsperformance
Challenge
- Inefficiencies in the indirect areas
- Long order lead times (from customer to customer)
- Lack of transparency in order processing
- Missing systematics for program planning
- Lack of connection to CRM
- High effort in technical order processing (variance, special design, configuration)
- Disproportionate personnel requirements compared to sales growth
Procedure
- Process surveys and analyses in the indirect areas (VSM, VSD, swimlanes, activity analyses, structured interviews)
- Identification of potentials and derivation of fields of action incl. Measures
- Evaluation and prioritization of measures and transfer to project planning
- Establishment of a continuous work mode of regular routines and work meetings
- Implementation support
Results
- Documentation of all indirect processes in order processing including weak points
- Effort/benefit assessment of all potentials
- Reorganization of order clarification
- Introduction of a variant configurator and connection to the CRM system
- Reduction of customer-related constructions by Ø 30%.
- Reduction of the order DLZ by Ø 20%
- Mapping of order growth of approx. 10% p.a. with unchanged staffing levels
The project in detail
Project Highlights
Contract manufacturing in single piece quantities
High customer requirements regarding optical product features
Holistic approach to optimization within the company
