Production
Digitize production:
Smart Factory Consulting and Lean Production Consulting
Smart Factory Consulting: Efficient. Connected. Future-proof.
Rising costs, volatile markets, and increasing customer demands call for a production process that is flexible, efficient, and data-driven. With our Smart Factory Consulting, you can lay the groundwork for intelligent, connected manufacturing and sustainably boost your competitiveness. Rothbaum supports you every step of the way, from optimizing your processes to successfully implementing the right smart factory solutions – thereby creating greater transparency, productivity, and future-proofing for your company.
Philipp Kappus
Senior Manager Production
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Are you planning the next step towards the Smart Factory? Then please send me a message. I will get back to you as soon as possible.
Determination of the status quo & maturity level
Recognizing the starting point, making potential visible
A well-founded analysis of your current maturity level is the first step towards targeted further development. As part of our Smart Factory Consulting, we evaluate your processes, systems and technologies in comparison to a clearly defined benchmark – and work with you to define realistic goals.
We work out the special features and challenges of your company in a targeted manner, uncover weaknesses and show where your greatest potential lies. Our Smart Factory Consulting supports you in translating the results of this analysis directly into a practice-oriented strategy.
Our service packages:
- Analyze your factory’s digital maturity with the Rothbaum Digitalization Check
- Evaluate current processes, technologies, and systems
- Identify opportunities for optimization and potential for efficiency gains
- Compare industry benchmarks and derive actions
Your benefit:
- Transparency Regarding the Status of Digital Development
- Clear Priorities for the Transformation
- Joint target definition with all relevant stakeholders
- Rapid Implementation of Initial Improvements
- Greater planning certainty for further digitalization
Lean Production
Stable, lean processes as the basis for lean production consulting
No smart factory without stable, lean processes. Lean production forms the basis for efficiency, flexibility and digital transformation. With tried-and-tested methods and a tried-and-tested approach, we create the conditions for continuously efficient production as part of our lean production consulting.
Our service packages:
- Implementing Stable and Efficient Processes as the Foundation for the Digital Factory
- Implementing the Rothbaum OPEX Methodology Toolkit for Sustainable Process Improvement
- Embedding Lean Principles in the Company for the Long Term
- Developing a company-wide lean culture
Your benefit:
- Foundation for the smart factory: stable, digital-ready processes
- Long-term competitiveness through continuous improvement
- Sustainable increase in performance of employees, managers and organization
Automation & robotics
Targeted use of machines, systems and technologies for digitalization in production
Automation not only increases efficiency and output, but also relieves your employees. The decisive factor here is not the principle of “more is better”, but the targeted, sensible use of suitable technologies. As part of our Smart Factory Consulting, we not only work with you to analyse which level of automation suits your factory, your processes and your maturity level – we also support you from selection to successful integration, both technically and organizationally.
Our service packages:
- Analyze and determine the optimal level of automation for your factory
- Select and implement suitable machines, equipment, and systems
- Integrating Robotic Technologies for Routine Tasks
- Implement automation solutions from both a technical and organizational perspective
- Supporting Change Through Targeted Change Management
Your benefit:
- Higher production capacity and process stability
- Flexible scalability of production
- Relieving employees of monotonous tasks
- Future-proof automation strategy
- Reducing the impact of the shortage of skilled workers
Data & IT systems
Creating transparency through the integration of real-time data and intelligent IT systems
Data plays a central role in digitalizing production – and beyond. We think about your value creation end-to-end and support you with our Smart Factory Consulting to identify precisely the data points that you really need along the entire process for key figures, decisions and automation – including a clean structuring of your master data and relevant real-time information. In this way, we create the basis for well-founded decisions, stable processes and a scalable IT infrastructure – tailored to your target image, whether on-premise, private cloud or public cloud.
Our service packages:
- Integrating Real-Time Data for Digital Production Control
- Using AI and Data Analytics for Process Optimization and Data-Driven Decision Making
- Ensuring IT security and adherence to compliance requirements in networked production
- Implementation of dashboards for clear visualization of the relevant key figures
Your benefit:
- Full transparency of processes in real time
- Fast, data-based decisions
- Continuous increase in efficiency through AI and data analytics
- Ensuring security & compliance in networked production
Sustainability & energy efficiency
Ensuring sustainable and resource-conserving value creation
Energy efficiency and sustainability have long been strategic success factors – even in the smart factory. Digitizing, networking and making processes more transparent also creates the basis for not only identifying ecological levers but also optimizing them in a targeted manner. Our Smart Factory consulting supports you in thinking about sustainability right from the start – with little additional effort, but with tangible economic and ecological benefits: through integrated data transparency, targeted measures and measurable impact.
Our service packages:
- Analysis of resource utilization and energy consumption in production processes
- Optimization of your factory taking into account the Green Factory principles
- Implementation of measures to conserve resources and make the production facility more environmentally friendly
- Support with progress tracking, certificates and sustainability reporting
Your benefit:
- Reduction of energy and operating costs
- Compliance with legal requirements
- Building a green corporate culture
- Measurable ecological impact
Roadmap & implementation of measures
Structured planning – targeted implementation
Structured implementation is crucial for success. With a clear roadmap and tailor-made measures, we support you in effectively realizing your smart factory goals – pragmatically, purposefully and results-oriented. The scope of our smart factory consulting services ranges from the definition of specific measures and responsibilities to the coordination and operational implementation of selected measures – always tailored to your needs and your organization.
The basis for this is a clear production strategy that defines goals, priorities and the right development path.
Our service packages:
- Development of a structured roadmap for achieving the Smart Factory
- Definition of concrete measures and milestones for implementation
- End-to-end Smart Factory consulting: support with the implementation and continuous adaptation of measures
- Monitoring and reporting of progress
Your benefit:
- Clear implementation steps and responsibilities for the realization of your Smart Factory goals
- Clear focus on your corporate and production strategy
- Efficient implementation through a structured approach
- Faster measurable results
FAQ
What benefits does lean production offer for digitalised manufacturing?
Lean production creates stable and standardised processes whilst reducing waste. This provides a reliable foundation for digitalisation: data can be recorded consistently and digital applications can be deployed in a targeted manner. Combining lean production with digitalisation helps companies to realise efficiency gains in the long term.
How do companies achieve real-time transparency in production?
The key lies in the seamless integration of machinery, production systems and IT applications. Production data is continuously recorded, consolidated and made available – for example via dashboards – for operational control. This enables deviations to be identified more quickly and well-informed decisions to be made directly within the production environment.
Where can robotics and automation be usefully applied in production?
Automation is particularly worthwhile for repetitive, ergonomically demanding or precision-critical tasks. However, whether a process is actually suitable also depends on factors such as the range of variants, process stability, flexibility requirements and cost-effectiveness. Rothbaum Consulting supports companies in identifying suitable opportunities and selecting the right automation solution.
How can companies use AI and data analytics in production?
AI and data analytics can utilise production data to identify patterns, deviations and opportunities for optimisation at an early stage, and, for example, to improve on-time delivery and prioritisation, or to reduce lead times, waiting times and costs. Possible applications range from process optimisation and quality analysis to the prediction of disruptions and production trends. Rothbaum Consulting identifies suitable use cases and assesses their data requirements, technical prerequisites and economic benefits.
How do companies use IIoT to achieve real-time transparency in production?
The Industrial Internet of Things (IIoT) connects machines, plant and IT systems, enabling the continuous exchange of relevant production data. This allows machine statuses, process times, downtime, quality metrics and energy consumption to be recorded and analysed in real time. For successful implementation, a consistent data architecture and functional interfaces are crucial, alongside the appropriate IIoT technology.
