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Management consultancy for lean production

The global manufacturing and logistics network is the operational core of every industrial company. In order to be able to react flexibly to both continuous and abrupt changes in market and customer requirements and to grow profitably at the same time, a permanent and controlled further development of the production systems is necessary.

This requires strategies and concepts that focus on process excellence, cost efficiency, innovation, a lean, customer-oriented organization and consistent digitization. This is the basis for manufacturing and logistics networks to make their contribution to securing the long-term competitiveness and profitability of a company.

This task is more than demanding. The manufacturing strategy must be derived from the corporate strategy and operationalized, the cost structures must remain lean while increasing flexibility, the opportunities arising from technological development and Industry 4.0 must be used in a targeted manner, and the increasing complexity must be mastered and reduced at the same time. In addition, employees must be qualified and empowered so that they can perform these tasks with confidence.

This requires a perspective that encompasses every relevant aspect of the industrial value chain: from strategic decisions and the development of the global production map (Global Manufacturing Footprint) to technologies, systems, processes and qualifications in the factory and the supplier network. 

The consultants of ROI-EFESO are the most recognized specialists for industrial transformation and best practice design of manufacturing and logistics.

Our comprehensive methodical know-how, technical and industry expertise as well as detailed knowledge of the relevant technologies, concepts and best practices around LEAN and Industry 4.0 make us an ideal partner in this demanding environment. 

In detail, our range of services in the field of production and logistics covers the following topics: 

Bild einer Maschine in der Autoindustrie
Case Study

Competition like in the Bundesliga: A leading global automobile manufacturer wanted to mobilize and accelerate its entire network of nine factories in terms of costs and quality. With ROI-EFESO, the group established a completely new, soccer-inspired practice of competing for a championship lead. The project team thus dynamized rigid factory structures and work routines.

Bild einer Industrieanlage
Case Study

The ROI-EFESO OPEX model: activate the forces of excellence. You learn from mistakes. It is important that continuous improvement is the result. In industry, this is targeted as "Operational Excellence", or OPEX for short. Instead of resorting to off-the-shelf solutions, companies should develop their own strategies here - like the group from the steel industry, which successfully used the OPEX model from ROI-EFESO in its plants.

Bild einer Montagestraße für Autos mit Robotrarmen
Case Study

Do you speak OPEX? Can you improve on a success story? Certainly, if you have a sense for the right fields of action. An automotive supplier is well-established worldwide, with around 20 successful plants in Asia, Europe and North America. Thanks to good customer proximity, the sites have developed good business relationships over the years and organised their production processes independently. But now it was time to share this knowledge among themselves. The method: by introducing OPEX (operational excellence) together with ROI-EFESO across the entire operation area.

Close-up einer Maschine
Case Study

A plant and mechanical engineering company had to ensure its competitiveness. ROI-EFESO identified all the adjustment screws for the necessary changes at a production site in Germany and got the turnaround going with a multi-layered restructuring approach.

Eine Fabrikhalle in der der ein Roboter die Arbeit verrichtet
Case Study

Special plant construction is a volatile project business with the smallest batch sizes, individual customer requirements and high complexity. Conflicting entrepreneurial goals of those involved make it difficult for companies to plan. In this complex market, ROI-EFESO developed a tailor-made factory of the future for a manufacturing company in order to increase the quality of the products, reduce costs and make projects more plannable.

Bild einer Industrienaemaschine
©HelloRF Zcool/shutterstock.com
Case Study

In China, the "made in Germany" label stands for innovative strength, quality and a high level of development competence on the part of the manufacturers. A textile machine manufacturer wanted to reduce the variance and complexity within the product portfolio. The main goals: reducing costs and strengthening the position in the Chinese market. With the China expertise of ROI-EFESO, a solid, regional supplier network was created in a short time.

Arbeiter an einer Fertigungsstraße
Case Study

Whether in the automotive, mechanical engineering or consumer goods industry: Quality problems are treacherous. If they remain undetected or ignored, they already cost a lot of money. In order to bring quality management to a new level of performance, the right combination of proven measures and new technologies must be found. With the lean supply chain management approach from ROI-EFESO, companies can develop in many ways in terms of quality.

Mann mit Klemmbrett in einer Fabrik kontrolliert die Fertigung
Case Study

Lean practice on the hall floor. With the ROI-EFESO lean training program, an industrial group improved its value-added processes at over ten locations. The program not only brought the different levels of knowledge of the managers in Lean Thinking down to a common denominator. With a multiplier approach, it also transferred the theory directly into work practice on the hall floor - from the first day of training.

Bild eines Laborarbeiters in der Elektobranche
©ARRI Group
Case Study

The highest quality standards are an indispensable part of day-to-day business in the pharmaceutical and life sciences industry. A medical technology company wanted to reduce the number of errors in the production line of one of its top products by a factor of 10. Together with ROI-EFESO, the company identified the right starting points and ensured quality increases that can also be scaled to other product lines.

Zwei sitzende Frauen klatschen
Lean Digital Manager ©S_L/shutterstock.com
Case Study

Shaping the factory of the future with Lean 4.0. How can lean principles be combined with the technologies and possibilities of networked digitization in value creation networks? By further qualifying employees to become decision-makers. The ROI-EFESO certification program for "Lean Digital Manager" shows how digitalization of lean production works. To do this, it combines strategies with Industry 4.0 technologies.

Case Study

Performance increase on the shop floor. Should every employee receive shift planning via smartphone? Or the plant management can compare solution proposals on a virtual dashboard in real time in the event of disruptions in the production flow? Thanks to the available IoT technologies, these and many other work simplifications of a digital shop floor management can be easily implemented today. Automobile manufacturers in particular like to take advantage of the opportunities offered by digitization and already have various systems in use, at all stages of maturity.

[Translate to English:] Warehouse 4.0, Intralogistik 4.0, Logistik
Case Study

Technological landmarks for ideal logistics: Technological landmarks for ideal logistics. Does a data goggle speed up picking? Or is an investment in a pick by light system more worthwhile? Up to now, new technologies for intralogistics have not been high on the priority list of companies. This is because the cost share of logistics is lower than that of other work areas and their need for digitization is generally greater.

ROI Case Studie - Smart Factory Planning
Case Study

What does the ideal factory of the future look like? Do products there control their production completely independently? A pharmaceuticals and life sciences company plans the main directions for the smart factory transformation of four plants in just one month. Together with ROI-EFESO, the project team creates a "big picture" as a basis for planning and tests three prioritized technologies in pilot projects.

ROI Case Studie - Lean Transformation
Case Study

In the lean production system of an automobile manufacturer, a premium model with a wide range of variants and vertical integration rolled off the assembly line. But then the new head of production set the goal of introducing two additional series on the same line within just five months. The company used this challenge to realign its production, increasing the volume of manufactured cars by 85%.

Frau mit Haarnetz bei der Produktion eines Chemie-Produkts
Case Study

The global demand for thermosets is increasing, as is the case in the energy industry. A manufacturer of thermosetting resins has positioned itself as a leader in the chemical industry by providing these customers with a variety of innovative technologies, solutions and specialty products. In order to be able to react even more efficiently to market changes and customer requirements in the future, the company is realigning its production network.

Case Study

End-to-end supply chain digitalisation in the healthcare sector. Putting together and ordering the desired product according to your own needs at the click of a mouse in the online configurator: these customer requirements must not only be met by companies in the consumer goods industry. This interaction is also highly relevant for manufacturers of medical, customisable products. However, whether assistants, support stockings or other products expand the B2C business in this way depends on the digital maturity of the logistics and production processes.

Detailaufnahme von der Fertigung eines Brillenglases mit Lichtspiegelung
Case Study

The Italian group Marcolin S.p.A. has been designing, manufacturing and selling sunglasses and optical lenses for well-known brands such as Tom Ford, Bally, Moncler, Sportmax and Ermenegildo Zegna for 60 years. In 2018, she sold more than 14 million pairs of glasses through 150 distributors in 125 countries. Optimal management of the fashion company's international supply chains and production processes is correspondingly important.

Aufnahme eines Lagers mit Gabelstapler zur Fabrik- und Logistikplanung
@Adobe Stock
Case Study

An automotive supplier consolidates four parts warehouses into one warehouse. Three distribution centers of a company from the automotive industry should be integrated into an existing fourth. With the support of ROI-EFESO, the company mastered this task in eight weeks. To do this, it developed five solution scenarios with different degrees of automation (“minimal invest” to “fully automated”) including layouts and monetary evaluation.

Detailaufnahme einer Machine in der Produktion
Case Study

The demand for high-performance plastics is increasing worldwide. A company in the chemical industry wants to increase the total capacity of its polymer production by more than 50% with a new plant complex. Together with ROI-EFESO, it is aligning its organizational structure to growth and profitability and is realizing an annually recurring benefit of more than EUR 1.5 million through process improvements.

Prozesseffizienze Produktion von kosmetischen Produkten
@Adobe Stock / Wayhome Studio
Case Study

A manufacturer of cosmetics and personal care items responds quickly to customer requests. High product demand leads to production bottlenecks at a market leader in the personal care industry. Together with ROI-EFESO, the company implements a complete shop floor management system - and increases output by up to 30%, depending on the line, with measures such as increasing the filling system cycle.

Case Study

An automotive supplier harmonizes production planning and control in ten factory locations around the world. With ROI-EFESO, the company develops a suitable solution concept for a suitable software solution. This enables a standardization of the planning process and thus more flexibility and efficiency. Likewise, a long-term capacity planning of the plant group can be carried out in the new software.

Case Study

A fast-growing manufacturer of medical consumables can no longer meet the rapidly increasing demand and is threatened with the loss of market share. The company needs a solution to significantly increase output in a short time.

Case Study

In order to achieve the self-imposed goal of being climate-neutral by 2050, a manufacturer of basic chemicals has to put its entire business model to the test. ROI-EFESO supported the client with robust scenario planning to develop a sustainability roadmap that enables sustainable growth in a challenging industry environment.

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Case Study

With hard targets for the entire operations area, a valve manufacturer is aligning a plant location for the future - and thus securing the site in Germany. Together with ROI-EFESO, the company restructures its manufacturing and logistics and achieves, among other things, an OEE of more than 85%.