Production is continuously changing, driven by evolving markets, introducing new technologies, new processes and new structures. The focus remains unchanged: High productivity and high agility constitute the foundation for lasting profits. 

High productivity requires robust processes within lean and tailored structures. Small batches and mass production undergo identical processes, and may see the same equipment. The production works in sync with customer takt time, at minimum inventories and swift quality feedbacks. The correct level of automation balances between speed, quality and reproducibility on one hand and lean manufacturing on the other. The staff is striving for perfection. 

Agility allows adjusting to fluctuating volumes, new products, and innovative technologies in a simple and flexible approach. Processes are changeable and scalable, personnel is qualified and highly motivated. Agility decreases the cost for change and enables a price premium from short time to market.

How to design your product for production? How to produce variants cost-effectively? What to manufacture yourself and what to buy in? Where to manufacture? How to integrate your suppliers? Which manufacturing principle to implement: workshop, island, line, or matrix manufacturing?

We advise you on defining your production and logistics goals and aligning your resources. We support your projects from potential analysis to implementation, e.g., of a new cross-location manufacturing structure.

The topics of our projects are:

• Product design: design-to-cost, standardization, variant management
• Process design: process cost calculation, vertical integration, make-or-buy, production sites, footprint, supplier network, production segments, production principle

How can you get production flowing, even with large products? Which manufacturing equipment to choose? How much automation and interlinking is economical? How to transport and store goods? Which layout creates short distances and enables flexibility? How can you grow step by step, both in your existing premises and with a new building?

In a creative dialogue, we develop a cost-effective overall concept with innovative detailed solutions for your task. We plan turnkey plants, from a blank sheet of paper to the approved factory. Also as general planners. 

The topics of our projects are:

• Factory planning: value stream, production segments, simulation of capacity requirements and movements, material flow, layout, facilities/infrastructure/buildings, cleanliness, environmental protection, greenfield vs. brownfield
• Process planning: Process engineering, plant engineering, automation, interlinking, energy efficiency, IT, control technology, machine and process data acquisition, Industry 4.0
• Logistics planning: Material supply strategy-by-part, simulation of movements/inventories, load carrier design, conveyor technology: warehouse technology/transport technology, order picking technology, IT, material flow, layout, buildings, fire protection

Our approach complies with VDI 5200 for factory planning.

How to implement lean production? What does it mean to manufacture in sync with customer demand? How to implement Kanban, supermarket, and JIS? How to implement “perfection” in manufacturing? How to adapt or introduce new systems?

We identify the causes of waste and performance barriers and design a program for the sustainable improvement of your manufacturing processes and QA procedures. Based on transparency and motivation, we pragmatically introduce the new processes with your team.

The topics of our projects are:

• Manufacturing consulting: SMED, OEE, fault analysis, visualization, CIP, FMEA, standards
• Logistics consulting: Flow principle, cycle time, pull principle, Kanban, JIT, JIS, supply chain management