Take your value creation to the next level with the help of operational excellence!

Lean and efficient processes are a prerequisite for Industrie 4.0!

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Operational Excellence in production

Operational Excellence in Production

In order to remain competitive in the face of high cost pressure, production processes must be continuously optimized - quickly, effectively and measurably. We support you in sustainably reducing your manufacturing costs while increasing quality, flexibility and sustainability. Through the targeted analysis of your production systems, we identify short-term savings potential in the planning processes, on the store floor and along the entire value stream. Through the focused use of the right lean methods and the implementation of cost-effective automation and digitalization, we create efficient solutions that make your production faster, more flexible and more cost-efficient - while conserving resources and safeguarding your future.

Unser Vorgehen zur Operational Excellence

Our Consulting Services for Operational Excellence in Production

Process optimization, production planning and control

Cost and quality advantages through excellent processes

Your challenges:

Unsynchronized processes hinder efficient operation
Many system breaks lead to extra work and coordination
High volatility on the supplier and customer side that cannot be mapped with existing processes

UNITY solution approach:

Holistic optimization of business processes in order processing - from order to delivery
Introduction of best-practice solutions from various industries
Strong focus on the impact on costs and earnings
Standardized process mapping

Shopfloor Management

Always at the optimum operating point thanks to fact-based management at the point of value creation

Your challenges:

Goals are not specifically defined, performance is not measured
Performance deviations are recognized too late
Defined standards are not put into practice
Problems are not actively identified and proactively solved

UNITY solution approach:

Development and implementation of key performance indicator systems
Implementation of active CIP and control loops
Integration of analog and digital solutions for store floor management
Empowerment of managers and employees through structured training and lean leadership programs

Value stream optimization

Increasing efficiency and reducing waste along the entire production process

Your challenges:

High inventories and long throughput times
High proportion of non-value-adding activities (waste)
Lack of clarity about bottlenecks in the process

UNITY solution approach:

Analysis and visualization of value streams to identify bottlenecks and waste
Target value stream design based on lean principles (pull systems, flow principle, etc.)
Reduction of throughput times and non-value-adding activities
Optimization of warehouse and WIP inventories

Automation and digitalization

Increasing efficiency and reducing errors through the use of technology

Your challenges:

High manual effort for activities that can be automated
Error-prone and uncontrolled processes
Monotonous and ergonomically stressful activities

UNITY solution approach:

Implementation of cost-effective automation with a short ROI
Use of work-supporting ergonomic work aids
Implementation of AI use cases in process monitoring
Implementation of assembly aids and worker assistance systems

Optimization of maintenance management

Maximizing system availability and minimizing downtimes through proactive maintenance strategies

Your challenges:

Lack of transparency regarding the condition of systems and machines
Insufficient planning and prioritization of maintenance measures
Excessive downtimes due to purely breakdown-related maintenance
High failure rates and unpredictable maintenance costs

UNITY solution approach:

Automation and optimization of maintenance processes to reduce downtimes
Introduction of structured maintenance management with clearly defined processes and KPIs for preventive and condition-based maintenance
Implementation of predictive maintenance through the use of IoT and data analysis to identify maintenance requirements at an early stage

Selection of our methods for achieving operational excellence

5S & Visual Management

Creating structures and increasing transparency

We support you in the introduction of 5S and visual management to make workplaces clear, safe and efficient. Together, we standardize processes, reduce waste and create clear orientation for all employees. Through consistent visualization, we promote personal responsibility, simplify day-to-day management and lay the foundation for sustainable process improvements. Together, we strive for lean and efficient production.
Kaizen Event

Rapid success through intensive improvement workshops

During our Kaizen Week, we work with your team to identify and eliminate waste directly on site. With structured workshops, targeted analyses and pragmatic implementation, we achieve measurable improvements in the shortest possible time. At the same time, we strengthen your employees' problem-solving skills and establish a culture of continuous development.
Six Sigma

Quality improvement through data-supported process optimization

With Six Sigma, we support you in systematically identifying sources of error and sustainably improving your processes. Through the targeted use of the DMAIC methodology, we increase quality, efficiency and customer satisfaction. Our structured, data-based approach ensures that improvements are measurable, repeatable and permanently anchored - for excellent results in production and service.
Low-Cost Automaton

Rethinking circular logistics - efficient, sustainable, economical

With low-cost automation, we identify simple and cost-effective automation potential directly in your production environment. Whether pick-by-light, simple gripper or conveyor systems. Together with your employees, we develop pragmatic solutions that can be implemented quickly and noticeably relieve your processes. This allows you to increase productivity and ergonomics without major investment.
Root cause analysis

Solving problems sustainably instead of fighting symptoms

We support you in systematic root cause analysis using proven methods such as the 5-Why or Ishikawa diagram. The aim is to identify the actual causes of errors and inefficiencies and eliminate them lasting. Through structured problem solving, we strengthen your teams' personal responsibility, improve processes and sustainably reduce error and rework costs.
Policy Deployment

Implementing strategies effectively and purposefully

With Hoshin Kanri (Policy Deployment), we help you to clearly structure your corporate strategy and consistently implement it operationally. Together, we develop transparent target cascades, prioritize initiatives and ensure that top-level targets are linked to the shop floor. Through regular review mechanisms, we create commitment and enable agile adjustments along the strategy process.
FMEA

Recognize and safeguard against risks at an early stage

We support you in carrying out FMEA analyses in order to systematically identify potential sources of error and derive preventative measures. Whether product, process or design FMEA - with structured moderation and proven methods, we increase the robustness of your products and processes. This allows you to minimize risks, increase customer satisfaction and meet the highest quality and safety requirements.
SMED

Minimize set-up times, maximize flexibility

With the SMED method, we support you in drastically reducing your set-up and changeover times. Through the targeted analysis and standardization of set-up processes, we separate internal from external processes, simplify work steps and reduce downtimes. The result: increased system availability, smaller batch sizes, faster response to customer requirements - and a significant increase in your production flexibility.