Production
Assembly and production planning
Production Planning for Scalable and Efficient Processes
To succeed in manufacturing today, you need more than just modern technologies and high-quality products. Efficient, flexible, and scalable processes throughout the entire value chain are crucial. With a holistic approach to manufacturing planning, we lay the foundation for higher productivity, lower costs, and sustainable growth. We support you in strategically advancing your manufacturing and assembly processes, in a practical, data-driven manner and with a clear focus on measurable results.
Philipp Kappus
Production Manager
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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:
- Developing a Planning Framework and Target Scenarios
- Define production and assembly strategy
- Select structure and production system specifically
- Optimize production processes
- Designing lean production
- Develop modularization and platform strategy
- Prepare for the strategic implementation of production concepts
Your benefit:
- Strategic clarity and a sound basis for decision-making
- Greater Efficiency Through Lean and High-Performance Processes
- Greater flexibility in the production system
- Manageable Complexity in the Product Portfolio
- Scalable production structures for sustainable growth
Line and assembly planning
Efficiency starts with the right layout – we redesign production
In production and assembly planning, we design comprehensive, future-proof manufacturing systems—efficient, flexible, and scalable. We analyze existing structures, identify weaknesses, and redesign production environments—from intelligent layout planning and lean material flows to precise assembly sequencing.
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 for production
- Develop production processes and layout concepts
- Integrate layout and space planning
- Conduct a simulation of material flow and process sequences
- Develop an implementation plan
Your benefit:
- Customized planning according to market and product requirements
- Holistic analysis with a focus on weak points
- Future-proof and flexible production concepts
- 2D and 3D models for realistic planning
- Close cooperation with your specialist departments
- 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 system. Our focus is on developing integrated material flow and logistics concepts that shorten transport routes, reduce inventory, and enhance supply reliability. In production in particular, significant losses arise from downtime, missing parts, or excess inventory when logistics processes are not precisely aligned with production requirements. That is why we place special emphasis on the seamless integration of logistics and manufacturing.
We optimize warehousing and fulfillment strategies, define cost-effective warehouse structures, and also develop concepts for demand-driven material fulfillment—for example, through supermarkets, pick-up shelves, or sequenced deliveries.
When implementing Kanban, milk run, or tugger train systems, we ensure a robust control system that reliably synchronizes consumption, replenishment, and supply. In addition, we support you in integrating modern technologies such as AGVs (Automated Guided Vehicles), AMRs (Autonomous Mobile Robots), and conveyor systems to make the most of efficiency, flexibility, and automation potential.
Our service packages:
- Analyze Material Flow and Assess Weak Points
- Designing Integrated Logistics and Supply Systems
- Optimize storage and staging strategies
- Planning and Integrating Logistics Automation Technologies
- Ensure synchronization of logistics and production
- Create implementation plan
Your benefit:
- Stable supply for production
- Minimized inventories and reduced capital commitment
- Lower transportation and handling costs
- Greater space efficiency thanks to intelligent storage and staging concepts
- More transparency and controllability in the material flow
- Future-proof thanks to scalable and automated logistics solutions
Workplace design and ergonomics
Efficiency and health combined: ergonomically optimized work systems
We design the workstations in your company in a way that benefits productivity, quality, and health in equal measure. This is based on an analysis of work systems from ergonomic, time-management, and organizational perspectives.
Using methods such as MTM or REFA analyses, we evaluate workflows and movements in detail—with the goal of reducing ergonomic strain on the one hand, and optimizing process times and enabling a balanced work design on the other.
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 Evaluation of Workstations and Work Systems
- Designing Workplaces That Promote Health and Optimize Processes
- Conduct and evaluate MTM- and REFA-based time and motion studies
- Optimizing Manual Tasks and Movement Patterns
Your benefit:
- Reduced physical strain and ergonomic risks
- Higher Productivity Through More Efficient Workflows
- Sustained employee satisfaction and lower turnover
- Improved Process Stability in Manufacturing
- Attractive and sustainable working conditions
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 opportunities for outsourcing, such as contract manufacturing or an extended workbench. In doing so, we take into account technological requirements, quality considerations, logistics connections, and flexibility goals.
Working closely with you, we develop a clear basis for decision-making regarding whether to handle tasks in-house or outsource them—right down to specific sourcing strategies. In addition to selecting suitable partners, we focus on structuring interfaces and management models, as well as establishing operational transparency. Consequently, our focus is on optimizing the entire production network: from relieving pressure on internal capacities to ensuring economic stability in volatile market environments.
In this way, we ensure confidence in decision-making and implementation—for an agile, cost-optimized, and high-performing production organization.
Our service packages:
- Conduct structured make-or-buy analyses at the process and component levels
- Develop sourcing strategies, including contract manufacturing and extended workbench
- Develop and optimize management models for external manufacturing partners
- Designing Efficient Interfaces and Logistics Processes
- Prepare a cost, risk, and flexibility assessment for in-house vs. outsourced manufacturing
- Implement KPIs and operational control mechanisms for performance monitoring
Your benefit:
- Transparency regarding vertical integration and core competencies
- Lower manufacturing costs through strategic outsourcing
- Flexibilization of capacities in the event of fluctuations in demand
- More resilient supply chains and reduced operational risks
- Improved Control of External Production Networks
- Sustainable Competitiveness Through Optimized Sourcing
Process optimization
Efficient processes are no coincidence – we design them systematically and sustainably
Our process optimization consulting services are designed to achieve sustainable improvements in efficiency, quality, and flexibility. Through value stream mapping, we not only create transparency regarding material and information flows, but also 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 shop floor workshops. We place a special focus on reducing waste, optimizing setup processes, and establishing clear standards. In addition, we improve takt times, cycle times, and lead times to ensure consistent, demand-driven production. This results in stable, adaptive processes that reduce costs, increase flexibility, and actively engage employees.
Our service packages:
- Conduct value stream analyses and develop target processes
- Designing Lean, Standardized, and Stable Processes
- Embedding Lean Management Principles in the Company
- Conduct and facilitate CIP and Kaizen workshops
- Systematically Identify and Reduce Waste (Muda)
- Analyze and Optimize Throughput, Takt, and Cycle Times
Your benefit:
- Lower litigation costs through optimized processes
- Higher productivity with the same use of resources
- Shorter turnaround times and faster response times
- Greater transparency and better control over production
- A Culture of Continuous Improvement Through Active Employee Participation
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 to make production more flexible, efficient, and data-driven. We help you systematically tap into the potential of Industry 4.0 and translate it into measurable benefits.
Key components include the integration of MES and ERP systems to ensure seamless information flows and maximum transparency from planning through production. With the help of digital twins and simulation models, processes can be validated in advance, bottlenecks identified, and well-informed investment decisions made. Machines that communicate with one another create transparency—and, thanks to AI, open up new avenues for stabilization, quality improvement, and early error prevention.
Our service packages:
- Developing Digital Manufacturing Strategies and Roadmaps
- Selecting and Integrating MES and ERP Systems
- Building Digital Twins and Production Simulations
- Designing and Implementing OPC UA-Based Networking Architectures
- Implement Data-Driven Optimization Methods (AI/ML)
- Digitize Manual Processes and Build Intelligent Dashboards
Your benefit:
- Greater transparency of processes, machines and key figures
- More efficient processes thanks to seamless system integration
- Reduced downtime and faster response times
- Well-founded decisions based on real-time data
- Early fault detection through simulation and predictive analytics
- 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 help you implement lean processes from order entry through delivery, identify bottlenecks, and make processes safer. With detailed planning tools, we enable dynamic, takt- and capacity-oriented control for optimal resource utilization and reliable delivery dates.
Modern shop floor management and KPI systems create transparency and promote rapid responses and continuous improvement. In addition, we implement Andon and escalation systems to detect and resolve deviations and disruptions at an early stage.
Our service packages:
- Analyze and Optimize Order Processing Workflows
- Implement and customize detailed planning tools
- Implement Shop Floor Management Systems
- Developing and Visualizing KPI Dashboards
- Implement Andon and Escalation Systems
- Conduct training and coaching on operational management and problem-solving
Your benefit:
- Improved adherence to delivery dates and delivery reliability
- Increased transparency and controllability of production
- Faster response to faults and deviations
- Optimized resource utilization and capacity planning
- Continuous process improvement through data-based key figures
- 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 product launches and product changes, a structured Advanced Product Quality Planning (APQP) process ensures that quality is taken into account from the very beginning. We support your company in aligning product and process development so that your readiness for series production, delivery capability, and quality goals are reliably achieved. Key elements include facilitating FMEA processes, test planning, and the creation of production control plans—always taking into account customer-specific and industry-specific requirements. In ramp-up management, we ensure both a smooth start to series production through coordinated schedules and stable processes and close interface coordination. In this way, we enable error prevention, stable processes, and quality right from the start.
Our service packages:
- Planning and Managing APQP Projects in a Structured Manner
- Facilitate and conduct design and process FMEA analyses
- Create inspection plans and production control plans
- Ensure and Document Process Approval
- Manage launch planning and milestone tracking for new products
- Coordinate the interfaces between development, production, and quality
Your benefit:
- Preventing errors early on rather than correcting them later
- Reliable and punctual production start-ups
- Compliance with customer, regulatory, and quality requirements
- Reduction of complaints and start-up losses
- Seamless collaboration among all departments involved
What is assembly planning?
Assembly planning involves the structured design and planning of all steps, resources, systems, and processes required for the preliminary and final assembly of a product. The goal is to design assembly steps to be efficient, error-free, and ergonomic, and to select the optimal assembly principle.
What is production planning?
Production planning is the conceptual planning of production processes and structures—that is, the design of workflows, system configurations, layouts, machine arrangements, and material flows. It forms the foundation for efficient and flexible production.
How can you optimize your manufacturing processes?
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.
