Holistic production optimization

Optimizing production areas is one of roeren’s core competencies. Production is always viewed as an integral part of an entrepreneurial organism that is linked to essential areas such as development, purchasing, controlling and human resources via numerous interfaces. In order to achieve an optimum in production, it is necessary to align the objectives and processes with adjacent areas. This project example illustrates an application in which the interfaces to and from production responsibilities were used to penetrate far into adjacent areas of the company in order to identify optimization potential for the entire company processes. In a manufacturing company, work was carried out over several years to restructure the production areas with the latest plant technology, an innovative planning system and the realignment of organizational responsibilities. In the process, the performance limits of production became clearly apparent, which enabled the step-by-step identification of potentials that were translated into suitable measures. Starting from the core process of value creation in production, significant improvements in the company’s results were realized by adjusting processes and rules right through to sales. This example underlines the relevance of a holistic approach that combines production optimization with overarching corporate goals.

Profile

Company size

Location

Germany

Period

1 year

Branch

Percentage of individual services

reactive situation stabilization
holistic concept development
risk analysis production performance

Challenge

Inefficiencies in the indirect areas

Long order lead times (from customer to customer)

Lack of transparency in order processing

Lack of a systematic approach to program planning

Lack of connection to the CRM

High effort in technical order processing (variance as well as special design and 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 including 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

Holistic approach to optimizing the company

High specific technical challenge

Tailor-made innovative solution

Sensible change management throughout the company

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