Facts & experience

Operational Excellence with clear results. Processes redesigned with measurable efficiency gains.

Manufacturing layout, LEAN programmes and SAP/D365 implemented so lead times fall, inventories drop and more output is achieved with less effort.

+23%

Higher operational efficiency

+12%

More output

−13%

Less production personnel

−18%

Lower inventory levels

Initial Status Quo

Full capacities but long lead times and delivery pressure

Plants were heavily utilised and the organisation fought with long lead times, overtime, inventory mountains and island IT. Layout, processes and systems had grown historically – LEAN was a buzzword but not anchored. Goal was to noticeably improve efficiency with new factory layout, clear LEAN standards and also within existing ERP systems.

Implementation

Our most important steps

Lessons Learned

What we identified as our main points

LEAN only works when layout, systems and metrics align.

Value stream before software

Process planning before IT

Those who simply hang their ERP onto old procedures automate chaos. Clear value stream design is the better basis.

Layout is an efficiency lever

Journeys cost money

Well-thought-through hall layout with flow segments and Kanban saves journeys, time and inventories – often double-digit efficiency leaps.

LEAN needs clear thinking models

5S, Kanban, visual management

Without standards, LEAN is just a word. With simple routines, improvements become measurable and repeatable.

Efficiency must arrive in EBIT

Order-to-cash and working capital

Shorter lead times and lower inventories don't just improve the feeling in production, but directly cash flow and result.