Cost reduction analysis

Process and Cost Analysis for the Development of Cost-Cutting Measures in the Coffee Production Network

As the manufacturing subsidiary of Tchibo GmbH, Tchibo Manufacturing GmbH is responsible for roasting, blending, grinding, and packaging coffee at its three locations in Hamburg, Berlin, and Marki. To increase competitiveness, the production network’s manufacturing costs were to be critically reviewed, and effective cost-reduction measures were to be developed.

In collaboration with Rothbaum Consulting, the planning and production processes as well as the manufacturing footprint were analyzed, and areas for optimization were identified and quantified using process mining and process simulation. Within three months, a comprehensive catalog of 18 measures was developed, representing potential savings in the mid-seven-figure range.

The comprehensive analysis concept made it possible to identify significant and effective savings potential. The collaboration with the Rothbaum team was extremely satisfactory for me.
Manuel Fliegel, Director Manufacturing, Tchibo Manufacturing GmbH

Systematically Identify Cost-Saving Opportunities Within the Production Network

Challenge

To enhance competitiveness, the production costs at the three plants in Hamburg, Berlin, and Marki should be critically reviewed. The goal was to identify effective measures for reducing costs and sustainably increasing profitability across the production network.

Implementation

The planning and production processes, as well as the manufacturing footprint, were analyzed in terms of their costs and opportunities for optimization. Using process mining and process simulation, potential process improvements were identified and quantified. Based on this analysis, a catalog of measures with specific cost-saving potential was developed.

Results

A total of 18 measures were developed in the areas of planning, environmental footprint, and operations. The measures were categorized into strategic development scenarios and further grouped into packages, each of which offers savings potential in the mid-seven-figure range.