// Projects / Operational Excellence

Introduction of lean manufacturing at the leading maker of door hinge systems

Reducing throughput time by 80% by introducing lean manufacturing was the goal of the leading producer of door hinge systems. This was accomplished, but the team comprising customer employees and BLSG consultants managed to achieve even more: delivery reliability and service levels were improved, inventories were reduced and the flow rate in production stages across two locations was increased. Along the way there, data and IT processes were analysed and adapted and various Kaizen measures implemented. Outside the core team, lean thinking was also promoted throughout the company in individual consultations and workshops (e.g. on setup optimisation through SMED).

Redesign of order processing at a medical technology manufacturer

How can order lead time from initial customer enquiry to delivery be radically reduced? In a heterogeneous portfolio ranging from series products to custom-made products, it is essential to establish clear standards in both administrative and value-adding processes. BLSG’s experts documented the target processes in detail and introduced comprehensive key figure reporting. In the end, their accurate implementation support and intensive transformation management resulted in a customer order process with improved lead times.

Increasing efficiency by optimising an automotive supplier’s shop floor

How in a short time can several plants in different countries be uniformly assessed and potential savings identified and implemented? That’s a tricky task that requires special measures.Read more

Global roll-out of our Deep Dive Program for an automotive supplier

The slowdown in car manufacturing has sent shockwaves throughout the global automotive industry, resulting in excess capacity across the automotive supply chain and a pressure to quickly boost performance and reduce costs.

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Planning and implementation of production control for a new production site

What can a young company do when its own success exceeds its capacities and it requires new production space? In such a situation, it is not easy to develop a material flow, information flow and layout concept based on lean production principles. There tends to be a lack of experience and know-how, with staff already heavily challenged by the constantly growing daily business.

Our client, a high-tech manufacturer of sensors, called on BLSG to help them master this situation. A concept for all production, logistics and order control processes, including layout, was then developed in intensive workshops. Variable and capable of growth, this concept meets the requirements of increased production volumes and at the same time represents an evolutionary step towards lean production. The BLSG consultants were present at crucial moments during and after the move to assure a smooth launch of the new processes in the new production facility.