Kleinmann & Consultants GmbH

Fields of advice


Preparing Operational Businesses in order to manage crisis in the best way. By Consulting as well as in an Interim-Management relationship

Health-Check with immediate actions

  • Scanning of the main company areas
  • Identification of „weak-points“ including improvement potentials
  • Roadmap with immediate actions to elliminate all handicaps

Product/Automotive development and launch control

  • Milestone-Management
  • Close meshed Supplier-Management in case of “Buy-parts” problems
  • Elimination of barriers in the production flow especially in the launch phase

Cost Optimization programs

  • Identification of the main cost drivers in the P&L
  • Clearing-House for spend control
  • Consequent measure control

Complete Reorganisation -> Rightsizing

  • Adjustment of the organization according to the future demand
  • Fit for a maximum flexibility regarding volumes and variants
  • “Breathing suppliers”

leanLean for the future

Lean manufacturing tools for improving quality, flexibility and efficiency

Defining and deploying KPIs in the company

  • Vision -> Strategy -> Objectives -> KPIs
  • Defining Key Performance Indicators (KPIs) – tailored specifically to the customer
  • Monthly performance metrics management with analysis and follow-up measures


  • Ideas management – harnessing the brains of the workforce
  • Introduction of kanban – the key to short throughput times (TPT) and low WIP
  • Reduced setup times – a prerequisite for flexibility and small batch sizes
  • Training programmes – how to become a “learning company”

TPM – how to develop a robust production environment

  • The 6 pillars of Total Productive Maintenance
  • 5-S as the catalyst
  • Determining OEE (Overall Equipment Effectiveness) and what to do about it

Organisation of production

  • Mastering complexity through modularisation and standardisation
  • Continuous production flow through lean factory layouts
  • Eliminating disturbance factors by analysing and controlling the planning process
  • From Lean to Industry 4.0


Increase in “qualificiency” – improved results through better quality

Anticipatory startup management/advanced quality management

  • Gateway system running parallel to development processes
  • Gate reviews incl. Pre-startup Gate Readiness Audits
  • Program Management Audit Tool (PAT)
  • Advanced Run&Rate Audit

Operational quality management in the factory

  • Manufacturing Quality Basics (MQB), fundamental improvements in quality
  • Quality circle organisation “Let‘s solve our own problems!”
  • “End-of-line quality control”
  • Programmes to minimise production rejects

Professional management of customer complaints

  • Long-term problem-solving – Effective PDCA (plan, do, check, act) management
  • Qup! – the problem-solving method
  • Regression optimisation
  • Professional crisis management

Improving supplier quality

  • Implementation of complete supplier quality assurance systems
  • Supplier rating and auditing
  • Strategic supplier development
  • Task force deployment

Advanced DevelopmentAdvanced Development

Quickly and efficiently to a ready-for-market product state

Development organization

  • Resource and capacity management
  • Project Management Office/PMO
  • Performance agreements for points of intersection
  • Ensure employee qualification

Development processes

  • Standardization of product development process
  • Management for degrees of product maturity
  • Gateway tracking
  • Change management
  • Escalation process for limit violations
  • Launch management / Run@Rate

Development cost management

  • Project cost calculation
  • Tracking of development cost
  • Project controlling/reporting
  • Determine development KPIs to increase performance

Development strategy

  • Development roadmap
  • Shared resources approach for cross-management
  • Value stream analysis/value engin. VA/VE
  • Product portfolio engineering
  • Define development strategies
    • Strategic goals
    • Key figures & measures