Production Optimization

Investment planning, process initiation (process, requirements, material flow, and procedural planning), and layout planning serve to optimize locations, production, and processes sustainably in line with technological, business, organizational, and ergonomic criteria in order to meet profitability and investment goals.

Holistic Production Optimization

Identifying optimization approaches with significant potential for optimizing costs

• improving margins
• educing fixed costs
• reducing quality costs

Improving customer satisfaction

• deliverability and punctuality
• shortening delivery times
• improving and safeguarding product quality

Defining KPIs

• upporting continual improvements in value creation
• defining ambitions and competitive targets for KPIs/benchmarks

Establishing a powerful, competitive production network

• optimizing international factors locations
• optimizing in-house production and purchasing (insourcing and outsourcing of skills and capacities)

Setting up an intelligent, integrated production system

• end-to-end proprietary production system
• establishing and implementing defined, central elements (5S, Kaizen, CIP, down to the shop floor, etc.)

Examples of results:

• Reduced product portfolio and optimized use and availability of capital
• Increased productivity, e.g. management of shortages, reduced downtime, reduced trials
• Improved product quality, e.g. corrective measures for faults and effective KPIs
  Global production strategies

Feasibility study

• Basic principles and aims
• Scenarios
• Investment volume/rough economic viability calculation
• Assessment of scenarios and proposal
• Masterplan

Location assessment

• Current situation
• Project aims
• Location solution concepts
• Estimated investment/detailed economic viability calculation
• Assessment of solution concepts and location proposal
• Proposal on how to proceed

Operating concept

• Product plan
• Product quantity planning
• Process design/material flow planning
• Requirements planning
• Production concept
• Rough layout with options
• Investment/cost calculation
• Assessment/concept proposal
• Master schedule

Operational planning

• Basic planning principles
• Layout
• Operational resource planning
• Requirements planning (media)
• Operational resource catalog and space requirements
• Investment and cost calculations
• Schedule
• Preparation for decision on implementation

Implementation support

• Construction owner support
• Overall project management or co-project management
• Coaching

Helbling Management Consulting has executed various Production Optimization mandates in a range of different sectors.