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Our latest Projects


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).

Transparency in critical product start-ups and delivery situations

Within a few weeks, BLSG process experts analysed an automotive supplier using value stream and PEP analyses. On the basis of the findings obtained, a detailed action plan was developed to realise the potential of a new vehicle project.

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.

Simulation of the production control of a battery production at an automotive OEM

A new product, a highly automated new manufacturing concept, new IT systems that have to be integrated into an existing system landscape, new requirements for safety and fire protection, the first internally manufactured component at the site that has to be delivered to JIS – so much uncharted territory harbours high risks and poses great challenges for the planning departments.

Proof of the efficiency of the control concept, worked out by BLSG operations experts, is now provided by an extensive information and material flow simulation.

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Simulation of the production and order control of seat systems for an automotive supplier

How does the brownfield planning of a production system for an automotive supplier react to fluctuations in volume, take rates and scrap rates? BLSG AG provided the assurance that the concept was robust enough to deal with these stresses by simulating the production concept based on defined stress scenarios and key performance indicators.