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”

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

Lean-Tools

• 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

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

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