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Consulting Lean Manufacturing and Logistics

The heart of every industrial company beats in its factory. Or in its manufacturing and logistics network. And it is precisely here that innovation and customer proximity, process excellence and adaptation ability, competitive costs, and the orchestration of a complex global network, streamlined organisation and systematic digitisation must be connected into an overall structure that is future-proof.

This task is more than challenging. The manufacturing industry must respond highly flexibly to challenges such as extreme market fluctuations, supply shortages, cost pressures and new competitors. It needs to find ways to ensure that strategic decisions stand the test of time, cost structures remain streamlined, the opportunities of Industry 4.0 are exploited and increasing complexity does not paralyse its capacity to act. And it must ensure that employees are adequately qualified and empowered so that they can confidently carry out these duties.

To do this, a perspective is required that includes every relevant aspect of the industrial value chain – from defining a strategy and developing the global map of manufacturing technologies, systems and processes at the plant up to the supplier network.

ROI is one of the most acclaimed specialists for transformation and development of manufacturing and logistics. Our extensive methodological know-how, technical expertise and detailed knowledge of key technologies, Industry 4.0 and lean concepts and best practices make us an ideal partner in this challenging environment.  In particular, our range of services in the field of manufacturing includes the following areas:

Case Study

Bild einer Montagestraße für Autos mit Robotrarmen
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Standards for operational excellence in an international group of plants

20 global plants of an automotive supplier have operated largely independent of each other. In order to tap Value creation potential, the company quickly built up the necessary OPEX know-how together with ROI and created structured operations processes that function internationally.

Case Study

Bild einer Maschine in der Autoindustrie
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Quality improvement in the automotive industry

A leading global automotive manufacturer wanted to mobilize and accelerate its entire network of nine factories in terms of costs and quality.

With ROI, the Group established a completely new football-inspired practice of competing for championship leadership. The project team thus dynamised rigid plant structures and work routines.

Case Study

Arbeiter an einer Fertigungsstraße
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Quality excellence

To bring quality management to a new level of performance, the right combination of proven measures and new technologies must be found. ROI's lean supply chain management approach enables companies to evolve in many ways in terms of quality.

Case Study

Bild einer Industrienaemaschine
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Reducing complexity through standardization

A textile machinery manufacturer wanted to reduce the variance and complexity within the product portfolio. The core objectives: cost reductions and strengthening of the position in the Chinese market. With ROI's expertise in China, a solid, regional supplier network was established within a short period of time.

Case Study

Bild eines Laborarbeiters in der Elektobranche
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Quality in production

A medical technology company wanted to reduce the number of defects in the production line of one of its top products by a factor of 10. Together with ROI, the company identified the appropriate starting points and ensured quality improvements that can also be scaled to other product lines.

Case Study

Bild einer Industrieanlage
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OPEX - ROI Model

A steel group implemented an OPEX strategy with ROI at almost 200 locations. The goal: to use energies for change not simply free, but focused and result-oriented. So that operational processes are not only better, but also excellent.

Case Study

Zwei sitzende Frauen klatschen
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Lean Digital Manager

The ROI certification program for "Lean Digital Manager" shows how digitization of Lean Production works. It combines Lean Management strategies with industry 4.0 technologies.

Case Study

Close-up einer Maschine
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Restructuring and cost reduction in mechanical engineering

A company in the plant and mechanical engineering sector had to secure its competitiveness. ROI identified all the parameters for the necessary changes at a production site in Germany and started the turnaround with a multi-faceted restructuring approach.

Case Study

Eine Fabrikhalle in der der ein Roboter die Arbeit verrichtet
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Factory of the future

In the complex world of special plant engineering, ROI developed a customised “Factory of the Future” for a manufacturing company to improve product quality, reduce costs and facilitate project planning.