Assembly and production planning

Production strategies and concepts

Individually tailored production concepts for lean, scalable processes

As a specialized operations consultancy, we support companies in developing and implementing the optimal production strategy. Together, we analyze whether make-to-order, make-to-stock or assemble-to-order is best suited to the products, market requirements and volumes – always with an eye on efficiency, flexibility and costs.

We analyze and identify the most suitable production system: whether it’s continuous flow production for high volumes, flexible workshop production for a wide range of variants or hybrid matrix production for complex product structures. We design the systems in such a way that they remain scalable and adaptable.

One focus of our advice on assembly planning and production planning is the introduction of lean production concepts to reduce waste and streamline processes. This is complemented by the implementation of modularization and platform strategies to make product variants manageable and speed up production processes.

We also promote close cooperation with product development in order to design products for assembly right from the start and thus make production processes more efficient.

We support you in making your production future-proof, efficient and competitive.

Our service packages:

• Develop a planning basis
• Define production and assembly strategy
• Select structure and production system specifically
• Optimize production processes
• Designing lean production
• Develop modularization and platform strategy
• Prepare implementation strategically

Your benefit:

1. Strategic clarity for your production
2. Creating a sound basis for decision-making
3. Increasing efficiency through lean processes
4. Increase flexibility in the production system
5. Making complexity in the product portfolio manageable
6. Securing scalable structures for future growth

Line and assembly planning

Efficiency starts with the right layout – we redesign production

In production and assembly planning, we design holistic, future-proof manufacturing systems – efficient, flexible and scalable. We analyze existing structures, uncover weak points and develop new production environments – from intelligent layout planning and lean material flows to precise assembly cycles.

We create an optimal machine layout, design lean processes and minimize waste along the entire value chain. Our customized assembly concepts – be it one-piece flow, cycle assembly or modular cell production – are always based on product structure, volume and variant diversity. We also provide targeted advice on how to manufacture several products on one line. Although this is challenging, it can be successfully implemented with well thought-out planning and a high degree of flexibility.

To reduce set-up times, we implement proven methods such as SMED and anchor flexible changeover processes in daily operations. We rely on digital factory planning and simulation. This allows us to validate scenarios, identify bottlenecks and reliably evaluate investments.

Our service packages:

• Create a planning basis
• Develop production processes and layout concepts
• Layout and space planning
• Simulation of material flow and process sequences
• Create implementation plan

Your benefit:

1. Customized planning according to market and product requirements
2. Holistic analysis with a focus on weak points
3. Future-proof and flexible production concepts
4. 2D and 3D models for realistic planning
5. Close cooperation with your specialist departments
6. Transparent scenarios for well-founded investment decisions

Material flow and intralogistics

Rethinking logistics: shorter distances, lower inventories, greater security of supply

We analyze and design the entire internal logistics process. The focus is on developing end-to-end material flow and logistics concepts that shorten transport routes, reduce inventories and increase supply security. Especially in production, considerable losses occur due to waiting times, missing parts or excess stock if logistics processes are not precisely aligned with production requirements. This is why we attach particular importance to the seamless integration of logistics and production.

We optimize storage and retrieval strategies, define economical warehouse structures and develop concepts for the demand-oriented provision of materials – for example via supermarkets, supply racks or sequenced delivery.

When introducing Kanban, milk run or tugger train systems, we ensure a robust control system that reliably synchronizes consumption, replenishment and supply. We also support you in the integration of modern technologies such as AGVs (Automated Guided Vehicles), AMRs (Autonomous Mobile Robots) and conveyor technology in order to make optimum use of efficiency, flexibility and automation potential.

Our service packages:

• Material flow analysis and weak point assessment
• Conception of integrated logistics and supply systems
• Optimize storage and staging strategies
• Planning and integration of logistics automation technologies
• Ensure synchronization of logistics and production
• Create implementation plan

Your benefit:

1. Stable supply for production
2. Minimized inventories and reduced capital commitment
3. Reduced transportation and handling costs
4. Greater space efficiency thanks to intelligent storage and staging concepts
5. More transparency and controllability in the material flow
6. Future-proof thanks to scalable and automated logistics solutions

Workplace design and ergonomics

Efficiency and health combined: ergonomically optimized work systems

We design the workplaces in your company in such a way that productivity, quality and health benefit in equal measure. The basis is the analysis of work systems from an ergonomic, time management and organizational point of view.

Using methods such as MTM or REFA analyses, we evaluate work processes and movements in detail – with the aim of reducing ergonomic stress, optimizing process times and enabling a balanced work design.

We develop ergonomically optimized workstations that facilitate material access, reduce gripping spaces and avoid fatigue. We take into account different qualifications and physical requirements.

Our service packages:

• Ergonomic analysis and workplace assessment
• Designing healthy workplaces
• MTM- and REFA-based time and motion analyses
• Optimization of manual activities and movement sequences

Your benefit:

1. Reduced physical strain and ergonomic risks
2. Higher productivity through optimized workflows
3. Ergonomic workstations to secure skilled workers
4. Close cooperation with your employees

Make-or-buy & external production

Determine the optimum depth of added value

In an increasingly volatile and complex production world, strategic decisions along the value chain are becoming more and more important. We support companies in making fact-based and future-oriented make-or-buy decisions– with the aim of optimally balancing their own vertical integration.

We analyze processes, cost structures and core competencies and identify external manufacturing potential, for example in the form of contract manufacturing or an extended workbench. We take technological requirements, quality aspects, logistics connections and flexibility targets into account.

Together with you, we develop a clear decision-making basis for in-house or outsourcing – right through to specific sourcing strategies. In addition to selecting suitable partners, we also focus on structuring interfaces, control models and establishing operational transparency. Our focus is on optimizing the entire production network: from relieving internal capacities to economic security in volatile market environments.

In this way, we create decision-making and implementation security – for an agile, cost-optimized and high-performance production organization.

Our service packages:

• Structured make-or-buy analyses at process and component level
• Development of sourcing strategies incl. contract manufacturing & extended workbench
• Development and optimization of control models for external manufacturing partners
• Designing efficient interfaces and logistics processes
• Cost, risk and flexibility assessment for in-house vs. external production
• Introduction of KPIs and operational control mechanisms for performance monitoring

Your benefit:

1. Transparency regarding vertical integration and core competencies
2. Reduction of production costs through targeted outsourcing
3. Flexibilization of capacities in the event of fluctuations in demand
4. Reducing delivery times and increasing delivery reliability by increasing vertical integration
5. Minimization of interface risks and quality losses
6. Transparency and controllability of external services through structured processes and KPIs

Process optimization

Efficient processes are no coincidence – we design them systematically and sustainably

Our process optimization consulting aims to sustainably increase efficiency, quality and flexibility. Through value stream mapping, we create transparency about material and information flows, identify bottlenecks and work with you to develop lean, robust target processes. As part of lean, kaizen and CIP initiatives, we establish practical routines for continuous improvement – for example through store floor workshops. A particular focus is on reducing waste, optimized set-up processes and clear standards. We also improve cycle, cycle and throughput times to ensure consistent, needs-based production. This results in stable and adaptive processes that reduce costs, increase flexibility and actively involve employees.

Our service packages:

• Value stream mapping and development of robust target processes
• Design of lean, standardized and stable processes
• Introduction and anchoring of lean management principles
• Implementation of CIP and Kaizen workshops
• Derivation of measures: Systematic identification and reduction of waste (Muda)
• Optimization of cycle, cycle and throughput times

Your benefit:

1. Lower costs thanks to lean and stable processes
2. Higher productivity with the same resources
3. Reduced throughput times and faster delivery capability
4. More transparency and better controllability of processes
5. Active involvement of your employees in improvement processes

Digital manufacturing / Industry 4.0

Digital networking for flexible, transparent and future-proof production

At the heart of digital manufacturing is the intelligent networking of processes, systems and machines in order to make production more flexible, efficient and data-based. We support you in tapping the potential of Industry 4.0 in a targeted manner and turning it into measurable benefits.

Key components are the integration of MES and ERP systems to create end-to-end information flows and maximum transparency from planning to production. Digital twins and simulation models can be used to validate processes in advance, identify bottlenecks and make well-founded investment decisions. Machines that communicate with each other create transparency – and open up new ways to stabilize, increase quality and avoid errors at an early stage thanks to AI.

Our service packages:

• Development of digital manufacturing strategies and roadmaps
• Selection of software and system integration of MES and ERP solutions
• Creation of digital twins and production simulations
• Design and implementation of OPC UA-based networking architectures
• Introduction of data-driven optimization methods (AI/ML)
• Digitization of manual processes and creation of intelligent dashboards

Your benefit:

1. Greater transparency of processes, machines and key figures
2. More efficient processes thanks to seamless system integration
3. Reduced downtime and faster response times
4. Well-founded decisions based on real-time data
5. Early fault detection through simulation and predictive analytics
6. Future-proof IT/OT architecture for scalable growth

Production control and order processing

Lean and transparent production control for greater efficiency

Efficient production control and order processing ensure transparent, on-time and flexible production processes. We support you in implementing lean processes from order entry to delivery, identifying bottlenecks and making processes more reliable. With detailed planning tools, we enable dynamic, cycle- and capacity-oriented control for optimum resource utilization and reliable delivery dates.

Modern store floor management and KPI systems create transparency and promote rapid responses and continuous improvements. We also implement andon and escalation systems to identify and rectify deviations and faults at an early stage.

Our service packages:

• Analysis and optimization of order handling processes
• Introduction and adaptation of detailed planning tools
• Implementation of store floor management systems
• Development and visualization of KPI dashboards
• Introduction of andon and escalation systems
• Training and coaching for operational management and problem solving

Your benefit:

1. Improved adherence to delivery dates and delivery reliability
2. Increased transparency and controllability of production
3. Faster response to faults and deviations
4. Optimized resource utilization and capacity planning
5. Continuous process improvement through data-based key figures
6. Greater motivation and personal responsibility on the store floor

Production start-up and ramp-up

Avoid errors before they occur – with well thought-out advance quality planning

For new start-ups and product changes, structured advance quality planning (APQP) ensures that quality is considered from the outset. We support your company in aligning product and process development in such a way that your series production readiness, delivery capability and quality targets are reliably achieved. Central elements are the moderation of FMEA processes, test planning and the creation of production control plans – always taking into account customer-specific and industry-specific requirements. In start-up management, we ensure a smooth start to series production through coordinated schedules, stable processes and close interface coordination. This enables us to avoid errors and ensure stable processes and quality right from the start.

Our service packages:

• Structured APQP project support
• Moderation and implementation of design and process FMEAs
• Creation of test plans and production control plans
• Securing the process release
• Start-up planning and milestone tracking for new products
• Interface management between development, production and quality

Your benefit:

1. Early error prevention instead of late reworking
2. Reliable and punctual production start-ups
3. Fulfillment of customer and standard requirements
4. Reduction of complaints and start-up losses
5. Efficient coordination between development, production and quality

Was ist Montageplaung?  

Assembly planning is the structured design and planning of all steps, resources, systems and processes required for the pre-assembly and final assembly of a product. The aim is to make assembly steps efficient, error-free and ergonomic and to select the optimum assembly principle.

Was ist Fertigungsplanung? 

Production planning is the conceptual planning of production processes and structures, i.e. the design of processes, system configurations, layouts, machine arrangements and material flows. It lays the foundation for efficient and flexible production.

Wie können Sie Ihre Fertigungsprozesse optimieren? 

You can optimize your production processes by using lean methods, adapting your processes, automation or digitalization, for example. This reduces throughput times, increases delivery reliability, improves quality and reduces costs – depending on the focus.