Lean Manufacturing / Lean-ERP (for Global Automotive Original Equipment Manufacturer)

The purpose of the project was the optimisation and standardisation of the company’s production network consisting of several manufacturing locations by integrating Lean Manufacturing and Enterprise Resource Planning into an enterprise-wide logistics and production template.

1) Lean-ERP at a Global Automotive Original Equipment Manufacturer

Amongst others, the project led to the following key improvements:

• Reduction of inventory levels and throughput time – The realisation of the pull principle led to a reduction of inventory levels in the range of 30% and an acceleration of throughput time up to 25%.
• Increase of productivity – The consistent application of the continuous improvement principle in combination with the virtues of state-of-the-art ERP supported processes lead to productivity gains of up to 20%.
• Cost savings – With a strong focus on the elimination of different kinds of waste throughout the production and logistics processes, the client was able to realise significant cost savings in the range of 10-20%

2) Reduction of Complexity at an international manufacturing company.

Amongst others, the project led to the following key improvements:

• Simplification of operations processes throughout the logistics material flow within the entire plant network.
• Set up of a strategic process and IT roadmap for the future development of logistics and supply chain processes.
• Conceptual design for streamlining the process and systems landscape with respect to lean principles.
• Reduction of inventory levels concerning work-in-progress, buffer areas and warehouse inventory.