Case Studies

Lead Time Reduction

Type of industry:

Electronics

Company:

SME

Duration:

6 Months / 23 Days

Company targets:

Improvement of delivery performance; cost reduction

Results:

Reduction of lead time from 116 days (average) to 2 days; 100% delivery performance

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DoE - Design of Experiments - Taguchi Method

Type of industry:

Automotive Supplier

Company:

SME

Duration:

7 Months / 40 Days

Company targets:

Assurance of product quality; stabilization and optimization of welding processes

Results:

Quality requirements to welding products are met reliably; welding processes are stable and even exceed the requirements given; NIO parts and rework are reduced to almost none

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SMED - Setup Time Reduction

Type of industry:

Mechanical engineering

Company:

SME

Duration:

1 Month / 3 Days

Company targets:

SMED: reduced setup time; increased flexibility

Results:

Reduction of setup time by 70% (240 minutes → 72 minutes)

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Type of Industry:

Service sector

Company:

SME (car dealership)

Duration (total / actual consulting days):

1 Week / 1 Day

Company targets:

Visual improvement of service reception; reduction of search times; lead time reduction of customer care; prevention of waiting lines

Results:

Reduction of customer talk time to an average of less than two minutes; improved customer satisfaction

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PDCA / Deming Circle - Systematic Problem Solving

Type of Industry:

Production of large-scale lifting units

Company:

SME

Duration (total / actual consulting days):

7 Months / 22 Days

Company targets:

Optimization of internal processes within the commercial department (order acceptance, purchase department, work preparation)

Results:

Reduction of defects and rework; increase of delivery performance from originally 50% to 97%; 100% delivery reliability

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Master Data Maintenance

Type of Industry:

Production of medical products

Company:

SME

Duration (total / actual consulting days):

11 Months / 56 Days

Company targets:

Creating and updating master data to form a basis for an optimum production (parts lists, working instructions, process sequences, etc.), production control and for optimum logistics (supermarket dimensioning, etc.); more detailed and transparent cost structure per product and reevaluation of the current product range

Results:

Master data is current and covers all products and their variants; standards for mnemonic part numbers are established and implemented; master data reflects the correct process sequences, incl. different possible process sequences per product (parameter dependent process selection); standards for implementation of new products and changes to existing products are established and include the related master data maintenance; a detailed and transparent cost structure per product is available

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VSA / VSD - Value Stream Analysis / Value Stream Design

Type of Industry:

Aviation Industry Supplier

Company:

SME

Duration (total / actual consulting days):

1 Month / 5 Days

Company targets:

Enhancing transparency regarding the operational structure; improving knowledge transfer from theory to implementation; identification of bottlenecks

Results:

Direct knowledge transfer on site; vision development; development and implementation of a master plan in three steps; reduction of waste and work in process; lead time reduction

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TPM - Total Productive Maintenance

Type of Industry:

Automotive

Company:

Group

Duration (total / actual consulting days):

10 Months / 220 Consultant Days

Company targets:

OEE increase by 10%; knowledge transfer from theory to implementation and everyday use; development of a top down reporting

Results:

Average OEE increase by 14%; more than 22 machines optimized; over 200 employees trained; conduction of 134 coachings; training of 3 TPM trainers; implementation of a TPM reporting from the inside out

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Customer Takt Time / Line-Balancing

Type of Industry:

Steelwork, Heavy Machinery Manufacturing

Company:

SME

Duration (total / actual consulting days):

12 Months / 50 Days

Company targets:

Takt time oriented production; reduction of inventories

Results:

Knowledge of customer takt time; production organized according customer takt time; significantly reduced inventories (1 piece)

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Kanban

Type of Industry:

Heavy Metal Industry

Company:

SME

Duration (total / actual consulting days):

2 Months / 42 Days

Company targets:

Reduction of missing parts; increase of production output; reduction of deployed resources; improved flexibility

Results:

Only the actually required resources are delivered to the production; reduced inventories; reduced setup times; employees assume more responsibility (as a result of the implementation of Kanban Boards); transparent material flow

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Line-Back

Type of Industry:

Production of Motorcycles

Company:

Group

Duration (total / actual consulting days):

8 Months / 168 Days

Company targets:

Reduction of missing parts at the assembly line; reduction of logistics/inventory space used at the assembly line to have room available for new variants; reduction of resources used

Results:

Logistics/inventory space reduced by 76% at the assembly line; assembly line resources combined; integration of additional variants without an increase of resources required; improved parts supply (reduced number of wrong parts at the assembly line); assembly space oriented workspaces

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Organizational Structure