Production
Operational Excellence
Achieving Higher Performance Through Operational Excellence
Companies achieve sustainable competitive advantages not only through their products, but also through the efficiency of their processes. This is precisely where Operational Excellence (OpEx) comes in. Working with you, we create the conditions for more efficient processes, higher productivity, and an organization that can respond flexibly to change. This allows you to increase your profitability and secure your company’s long-term success.
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 address this challenge and holistically optimize your operations, we begin by conducting a detailed analysis of the current and target states. First, we work with you to define the premises and objectives based on your corporate strategy. Second, we analyze the current situation through interviews and workshops—from the shop floor to the management level—as well as process mapping, ERP evaluations, and benchmarking against reference processes and tailored KPIs. In doing so, we analyze all areas and identify weaknesses in order to, among other things, improve OEE and optimize the value stream. Based on the individual requirements of your company and your customers, we then develop a strategic concept with a tailored system of key performance indicators for your operations. On this basis, following an initial pilot phase, the measures are implemented on a sustainable basis.
Our Service Packages:
- Define the current and target states together
- Develop an operational excellence strategy based on the company’s goals
- Develop a tailored key performance indicator system
- Systematically identify vulnerabilities
- Develop targeted measures
Benefits for you:
- Objective analysis of the value creation process (view from the outside)
- Integration and coordination of all areas involved
- Appropriate goals and KPIs to measure success
- Transparent project planning
Philipp Kappus
Senior Production Manager
Feel free to contact me!
Ready to take the next step toward operational excellence? Send me your inquiry.
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.
In addition, we optimize production controlling using appropriate methods and tools. This ranges, for example, from a custom-designed Excel template to the selection and implementation of standard software such as a Manufacturing Execution System (MES) or Production Data Acquisition (PDA). To increase equipment availability and thus overall equipment effectiveness, we use proven methods such as Total Productive Maintenance. In doing so, we also identify opportunities to reduce setup time and optimize the value stream. Overall, these optimization measures help you achieve your production logistics goals, increase your production output, and achieve a faster and greater leap in quality than your competitors.
Our Service Packages:
- Expand the key performance indicator system to include the shop floor level
- Optimize production controlling with targeted tools
- Select appropriate software solutions (e.g., MES and BDE)
Benefits for you:
- Transparency about your cost structure
- Optimal standardization in your operating environment
- Higher productivity at lower costs
- Improved delivery capabilities and customer satisfaction
- Greater flexibility in the face of market and demand fluctuations
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. This includes, for example, improving OEE, reducing setup time, and optimizing the value stream.
To implement a tailored continuous improvement process (CIP), we use various proven quality management methods within the context of KAIZEN. The goal of CIP is to steadily improve quality and performance in operations step by step, based on key customer requirements, while optimizing OEE. Clear standards and tailored KPIs enable end-to-end performance measurement and continuous performance management. This allows, for example, measures to improve OEE, reduce setup times, or optimize the value stream to be systematically evaluated. As a result, top management always has a clear overview and can make targeted decisions. Our goal is to involve all employees in the implementation process and empower them accordingly to foster a sustainable cultural change.
Our Service Packages:
- Develop and implement a continuous improvement process (CIP)
- Define and implement standards and methods
- Empower and actively engage employees
- Establish management and control structures
Benefits for you:
- Sustained improvement in quality and performance
- Faster response to market changes
- Continuous identification of new opportunities for improvement
- Transparent management through measurable metrics
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.
To create a transparent, efficient, and interconnected organizational structure, we analyze and optimize current structures and the system landscape across all departments. In doing so, we also examine the interfaces along the value stream to optimize it and systematically identify opportunities for improvement. To ensure sustainable optimization, we develop and establish regular performance reviews. On the shop floor, for example, we implement daily performance monitoring, which helps improve OEE, among other things. And at the management level, we implement structures to regularly evaluate economic performance within the context of operational performance. This promotes continuous reflection and the realization of opportunities to optimize operations. Furthermore, deviations can be identified early, and appropriate corrective actions can be initiated.
Our Service Packages:
- Optimize organizational structures, systems, and interfaces
- Establish performance reviews and regular communication
- Measuring and Managing Operational Performance Using KPIs
Benefits for you:
- Increasing transparency, efficiency and networking of organizational structures
- Early detection of inconsistencies
- Identification of potential in the system landscape
- Sustained improvement in operational performance
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, we use value stream mapping to create a detailed overview of all end-to-end business processes and identify opportunities for value stream optimization. In doing so, we use modern tools for analysis, modeling, and simulation — such as process mining— to identify weaknesses and opportunities. This allows us to improve process quality by, for example, reducing production and setup times or improving and stabilizing on-time delivery rates. With the help of Robotic Process Automation (RPA), it is also possible to automate certain process flows and decisions, thereby reducing effort.
Our Service Packages:
- Analyze, model, and simulate logistics and production processes
- Identify weaknesses and areas for improvement
- Implement modern tools such as process mining and automation solutions
- Develop specific measures for process optimization
Benefits for you:
- Exploiting unused potential in operations
- Increasing process efficiency and transparency
- Minimization of manual routine tasks
- 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 also poses a major challenge. Often, the underlying problem involves unclear or inconsistent responsibilities and an inadequate management approach. Consequently, quality may suffer in certain areas, leading to increased costs and a higher frequency of errors. Operational excellence means establishing clear leadership structures and a strong culture of accountability.
Using the methods and principles of Lean Management, we work with you to develop a leadership concept that promotes quality while minimizing waste and costs. Lean management focuses on customer orientation and the prevention of waste, building on the principles of lean production in a generalized and further developed form. The cross-functional integration of lean principles fosters a high-performance culture in general and a culture of learning from mistakes in particular. As a result, employees are better equipped to avoid risks, optimize the value stream, and meet both customer requirements and corporate strategy—which lays the foundation for long-term business success.
Our Service Packages:
- Develop a management strategy to improve quality
- Implement lean principles across all departments
- Define responsibilities and standards
- Provide targeted training and development for employees (e.g., through training programs)
Benefits for you:
- Reduced risks and waste, coupled with a stronger focus on the customer
- Streamlined and clear structures and standards
- A high-performing, flexible, and open culture of accountability
FAQ
How does Rothbaum Consulting help shape the implementation of Operational Excellence?
Our Operational Excellence consulting begins with a structured analysis of your processes, organization, and key performance indicators. Based on this analysis, we develop a customized strategy and support you through the implementation process—from optimizing individual processes to introducing performance management and embedding a culture of continuous improvement. In doing so, we ensure that the improvements achieved are sustainable over the long term.
What results can be achieved through operational excellence?
Through operational excellence, companies can sustainably improve their process quality, delivery capability, and productivity. At the same time, they can shorten lead times, reduce waste, and lower costs. Clear metrics, standardized processes, and the active involvement of employees create a high-performing organization that can respond flexibly to new demands.
