Operational Excellence

As-is analysis and strategy development

The foundation to take your processes to the next level

Competition is too cost-intensive, high customer requirements cannot be met, quality and efficiency are inadequate: there are many indicators that potential in operations is not being fully exploited. The result is often that targets are not achieved and profits are lost. The major challenge is to recognize the most important potential for improvement and to systematically implement it in the spirit of operational excellence.

To overcome this challenge and optimize your operations holistically, our first step is to examine the current and target status in detail. Firstly, we work with you to define the premises and objectives based on your corporate strategy. Secondly, we analyze the current situation by means of interviews and workshops from store floor to management level, as well as process recordings, ERP evaluations and benchmarking with reference processes and tailored KPIs. All areas are analyzed and weak points identified. Based on the individual requirements of your company and your customers, we then derive a strategy concept with a tailor-made KPI system for operations. After an initial pilot phase, this forms the basis for the sustainable implementation of the measures.

Our service packages:

• Joint definition of the actual and target status
• Derivation of the operational excellence strategy based on the corporate objectives
• Development of a customized key figure system
• Drawing up a catalog of weak points
• Derivation of targeted measures

Your benefit:

1. Objective analysis of the value creation process (view from the outside)
2. Integration and coordination of all areas involved
3. Appropriate goals and KPIs to measure success
4. Transparent project planning and performance measurement

Performance management

Optimize performance, delivery capability and system effectiveness with Operational Excellence (OpEx)

Short product life cycles, a decreasing willingness to pay and an increasing number of variants are driving pressure to produce as many products as possible as quickly and cost-effectively as possible. On the one hand, throughput times and delivery reliability must be reduced and errors caused by damage in the production process, for example, must be avoided. On the other hand, rising costs for materials and personnel as well as an uncertain market situation demand transparent and flexible cost structures.

In order to improve quality and efficiency in manufacturing and business processes, we rely on tailor-made, proven methods for performance management, such as Six Sigma. The aim is to identify cost drivers and design waste-free processes. On the one hand, you gain transparency about your own cost structure and can sustainably reduce manufacturing costs. On the other hand, this increases customer satisfaction through faster throughput times and greater delivery reliability. At the same time, this contributes to greater flexibility, for example in the event of fluctuations in demand or individual customer requirements.

We also optimize production controlling using suitable methods and tools. This ranges, for example, from an individually tailored Excel template to the selection and introduction of standard programs such as manufacturing execution systems (MES) or production data acquisition (PDA). We use proven methods such as Total Productive Maintenance to increase plant availability and thus overall plant effectiveness. All in all, the optimization measures help you to achieve your production logistics goals, increase your production output and achieve a faster and higher quality leap than your competitors.

Our service packages:

• Expansion of the KPI system to include the store floor level
• Optimization of production controlling with targeted tools
• Selection of suitable standard software (e.g. MES and BDE)

Your benefit:

1. Use of proven methods (e.g. Six Sigma)
2. Transparency about your cost structure
3. Optimal level of standardization in your operations landscape for operational excellence

Continuous improvement

Continuously increasing competitiveness with operational excellence

If a continuous improvement process is not implemented, there is a high risk that performance levels will quickly drop again. Such a process is also essential in order to react quickly and dynamically to market changes. This is precisely where operational excellence comes in: A continuous optimization process makes it possible to identify and exploit precisely those potentials that are most important and target-oriented for the individual requirements of the organization and the market.

In order to implement a tailor-made continuous improvement process (CIP), we use various proven quality management methods in the context of KAIZEN. The aim of the CIP is to continuously improve the quality and performance of operations, step by step, based on key customer requirements. Clear standards and precise KPIs are used to continuously measure success and ensure ongoing performance management. This means that top management always has an overview and can make targeted decisions. Our aim is to involve and empower all employees during the introduction in order to create a sustainable cultural change.

Our service packages:

• Development and implementation of a continuous improvement process (CIP)
• Definition and introduction of target-oriented standards
• Involvement and empowerment of employees
• Development of structures for continuous performance monitoring by management

Your benefit:

1. Holistic cultural development for continuous improvement of customer benefit
2. Rapid response to market changes through standards and agile processes
3. Overview of current quality and performance by measuring success in operations

Organizational excellence

Holistic organizational development and change management

Organizational structures often lack clarity, meaningful networking and communication. In some cases, relevant interfaces between departments are not sufficiently defined. Quality problems, for example in supporting processes, can also have a negative impact on organizational excellence.

In order to create a transparent, efficient and networked organizational structure, we analyse and optimize the current structures and system landscape across all divisions. To ensure sustainable optimization, we develop and establish regular performance reviews. For example, we introduce daily performance monitoring on the store floor. And at management level, we implement structures to regularly evaluate economic performance in the context of operational performance. This promotes continuous reflection and the realization of potential for optimizing operations. In addition, deviations can be identified at an early stage and appropriate countermeasures initiated.

Our service packages:

• Optimization of organizational structures, systems and interfaces
• Performance management: development and implementation of regular performance reviews
• Regular measurement of operational performance with suitable KPIs

Your benefit:

1. Increasing transparency, efficiency and networking of organizational structures
2. Early detection of inconsistencies
3. Identification of potential in the system landscape

Process excellence

Recognizing and exploiting potential in process flows

Processes often lack transparency and efficiency. In many areas, process and work structures are also too inflexible to react to changing requirements. Overly complex process structures also make it difficult to identify errors and deviations and assign the causes. To counteract this, we use proven methods of process management (business process management).

First of all, we use value stream mapping to create a detailed overview of all end-to-end business processes. We use modern tools for analysis, modeling and simulation, such as process mining, to identify weak points and potential. Process quality can be increased accordingly, for example by reducing production times or improving and consolidating delivery reliability. With the help of robotic process automation (RPA), it is also possible to automate certain process sequences and decisions and thus save costs.

Our service packages:

• Analysis, modeling and simulation of all logistics and production processes
• Identification of weak points and optimization potentials
• Use of modern tools for simulation and automation such as process mining or RPA
• Development of concrete measures for process optimization

Your benefit:

1. Exploiting unused potential in operations
2. Increasing process efficiency and transparency
3. Minimization of manual routine tasks
4. Reduction of process complexity and susceptibility to errors

Leadership, people and culture

Agile improvement process with an active error culture for operational excellence

In addition to excessive complexity in structures and processes, a lack of staff qualifications is also a key challenge. The underlying problem often includes unclear or inconsistent responsibilities and an inadequate management concept. As a result, quality can suffer in certain areas, which is associated with increased costs and error rates. Operational excellence means establishing clear management structures and a strong error culture.

Using the methods and principles of lean management, we work with you to develop a management concept that promotes quality while minimizing waste and costs. Lean management focuses on customer orientation and avoiding waste and takes up the principles of lean production in a generalized and further developed form. The cross-departmental integration of lean principles promotes a high-performance culture in general and an error culture in particular. This puts employees in a better position to avoid risks and meet both customer requirements and corporate strategy – which lays the foundation for long-term corporate success.

Our service packages:

• Development of a management concept to improve quality
• Cross-departmental establishment of lean principles
• Targeted qualification of employees (e.g. through training)

Your benefit:

1. Reduction of risks and waste with greater customer focus
2. Lean and clear structures and standards
3. Promote a high-performance, flexible and open error culture