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LEAN MANAGEMENT

 

Results through lean processes and structures

We support our customers in implementing lean management methods and tools and in establishing the necessary corporate culture. We are a capable partner for our customers on the path to top performance, from the first steps to the development of a lean business system.

Lean Transformation

Lean transformation means improving an entire process chain of a company. We also design the network of value streams and reduce complexity. During a transformation, we optimize our customers’ entire value streams using our specific approach.

 

The goals of transformations are:

  • lean design of process chains/value streams within a short period of time
  • increasing the effectiveness and quality within the value streams based on data and facts
  • design and implementation of the appropriate key performance indicator system
  • implementation of daily operational coordination with the employees involved
  • introduction of effective value stream management with corresponding role and responsibility structures

 

Our approach is based on a holistic approach that primarily includes the ideas of employees, i.e. those who “live” the processes every day. To do this, we develop suitable change concepts with our customers. We base the transformational approach on the extended principles of lean management:

To transform an entire company, establish a lean corporate culture, and design its functions and value streams in a lean manner, we support this process by building a suitable business system through our Lean Business System Design services.

Value stream management

Value stream management (VSM) is an essential element of our approach to implementing lean management. We focus on the analysis, design and management of value streams in order to achieve increased efficiency and better customer orientation. The key components of value stream management are:

 

  • Development of a value stream and macro process map for the entire company
  • Definition and prioritization of the relevant product/service families
  • Value Stream Mapping
    • Visualization of the current state of a value stream
    • Recording of processes, lead times, inventories and information flows
    • Identification of waste (Muda), bottlenecks and potential for improvement
  • Value Stream Design
    • Development and visualization of the future state
    • Use of control mechanisms such as Kanban or Heijunka for process optimization
    • Introduction of lean principles such as one-piece flow, pull systems and cycle times
  • Tactical implementation planning and control
    • Development of an implementation plan with concrete measures
    • Definition of KPIs to measure success
    • Continuous improvement (Kaizen)
  • Use of shop floor management methods for sustainable control and improvement

 

We implement value stream management through a series of kaizen workshops for each value stream. We systematically integrate value stream management into our approach to strategy implementation, management and improvement routines and the three pillars of improvement.

Shopfloor Management

We support our customers in implementing effective shopfloor management. Shopfloor management essentially means line-level management at the place where value is created and the formation of semi-autonomous work groups. Employees are empowered to coordinate, make decisions and implement measures independently and autonomously.

 

The aim is efficient and effective control and problem solving on site and to achieve smooth and stable processes. Components of shopfloor management are:

  • Visual management and definition of practically relevant parameters (+QDIPS)
  • Structures of daily coordination on site / short-interval control
  • Structured and practical problem solving and continuous improvement
  • Optimization of communication and working with deviations (defect culture)
  • Effective escalation processes across different coordination levels
  • Practicing leadership culture at the place where value is created
  • Connection to goal coordination and strategy implementation (Hoshin Kanri)

 

We empower managers and teams to lead and guide the shop floor management process through specific coaching and process support. In addition to tools and methods, shopfloor management strongly relates to leadership behavior, expected behavior of employees, communication and information flow.

The future belongs to those who are better at getting better.

Kaizen and Kaizen Facilitation

In addition to establishing daily continuous improvement, we conduct intensive workshops (Kaizen workshops) to quickly improve the current situation together with the teams at the process level at our customers’ sites.

 

In this way, specific subject areas (e.g. efficient workplace organization, reducing setup times, process standardization, etc.) can be efficiently implemented in the form of workshops with direct employee participation.

 

A Kaizen workshop is carefully planned and carried out by a team within 3-5 days of intensive work. The result is concrete improvements for the work area, systems and processes.

 

We conduct different types of Kaizen workshops with our customers on site:

  • Value stream management with value stream analysis and design
  • Standard work and balancing (production and services)
  • Implementation of lean logistics concepts (pull concepts, including Kanban)
  • Set-up time reduction (SMED)
  • Problem solving (DMAIC)
  • 5S (workplace systematization)
  • Process optimization in administration/transaction-oriented processes
  • TPM-Kaizen (Total Productive Maintenance-Kaizen) for machine and system optimization

Each type of Kaizen workshops comes with its specific methodological agenda. We conduct appropriate methodological training for each Kaizen and integrate the workshop into the improvement organization through a closing event (report-out). The organizational lead time for a workshop can be set at around 20 days, and 30-45 days to complete any outstanding work.

Total Productive Management (TPM)

For companies with machine and equipment usage, we supplement our services with comprehensive and lean plant management based on the TPM approach. We support you in successfully implementing the principles of Total Productive Management (TPM). The goal is to maximize the efficiency and availability of your plants while minimizing operating costs. Our services include:

 

  • Current analysis and weak point identification: We carry out a detailed analysis of your current maintenance processes and identify optimization potential
  • Strategy development: Together we develop a tailor-made TPM strategy that is perfectly tailored to your production requirements
  • OEE optimization (Overall Equipment Effectiveness): Improving plant effectiveness by reducing downtime, waste and speed losses
  • Education and training: We train your employees in the TPM principles and ensure that they are able to contribute independently to continuous improvement
  • Implementation and support: From the introduction of autonomous maintenance, optimized cleaning plans and routines, preventive maintenance to predictive maintenance and repair – we accompany you step by step
  • Key figure development: Implementation of KPIs to monitor and continuously improve plant performance
  • Audits & assessments: Regular TPM audits to identify improvement measures and sustainable implementation of TPM principles

 

We integrate TPM into your lean management system and include extended elements such as plant management, spare parts strategy and optimization, maintenance management and information flow, master data quality, suppliers of spare parts and services and modern approaches to AI-supported maintenance and repair. In this way, we systematically expand the traditional “8 pillars” approach.

 

Our tailor-made solutions help you to minimize production downtime, improve product quality and secure long-term competitive advantages. With our support, you can transform your maintenance into a strategic pillar of your company and sustainably increase your competitiveness!

Why the AMELSBERG GROUP?

We are your reliable partner in the design of lean business systems and support you customers in this process over the long term. We are not only methodologically adept, but also clearly explain where priorities lie and what needs to be done.