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Analysis and optimisation of production processes with regard to:

Productivity
- OEE
- Downtime
- Technology consulting
- Lean Six Sigma
- Shop floor management
- Organisational development
Quality
- Internal scrap
- Customer complaints
- Maturity level
- Quality management culture/coaching
- VDA Core Tools
- Gap analysis/process audit

  

 

 

 

  

A methodical approach by:

> Process analysis (Sankey, VSM, Lean 6 Sigma)
> Gemba walk and data analysis
> Process and risk assessment (FMEA, RCCA, etc.)
> Workshop and team organisation
> Implementation of control loops
> Workstation design and 5S
> Poke Joke, Kanban and FIFO
> Process standards and procedure documentation
> defect analyse & documentation and -catalogue

Ensuring capacity and quality (launch and series production)

Ramp-up
- FMEA and control plan
- RCCA and MSA
- APQP and PPAP/PPF
- QVP and container project management
- SCM & load carrier management
- Tool management
- Escalation management
Pre-series & Serial ramp-up
- Team leadership for problem-solving (task force)
- Run@Rate and Lessons Learned
- Internal and external process audits
- OEE optimisation, SPC and cpK
- PPAP and maturity level
- LOP & PDCA
- SQM and SQA
- Complaints management
- Operations coaching, KPIs & shop floor management

 

A methodical approach by:

>  PPAP, PEP and APQP (quality processes and procedures)
> In-depth knowledge of IATF 16949, VDA 6.3, ISO 9001 internal auditor
> Plant and machinery optimisation
> Expertise in processes for the machining/processing of plastics and metals for:
- Interior (glove compartment, storage compartments, centre console, trim panels, decorative strips, etc.)
-  Exterior (bodywork, bumpers, spoilers, lights, etc.)
-  Electrical systems (sensors, ... etc.)
> Analysis of measurement data and > control of G-gates
> Implementation of quality improvement (control loops)
> Development, design and introduction of storage concepts
> Presentation of components for evaluation and coordination
> Tracking and validation of tools
> Implementation of control loops

Relocation of sites, facilities, machinery and production lines / Transformation support

Concept development
- Site assessment
- Gap analysis in accordance with VDA (ISO 9001 / IATF 16949)
- Potential analysis and supplier evaluation
Planning
- Team organisation and team leadership
- Milestone and project planning
- Investment planning and technology consulting
- Engineering and layout planning
Execution/Implementation
- LOP
- Escalations- und Stakeholder Management

 

 

 

 

A methodical approach by:

> Agile project management and PDCA cycle
> Creation of master plans, milestone and sub-project plans
> Communication and consulting for change processes
> Workshop and team organisation
> Implementation of control loops and meeting routines
> Training and instruction on VDA Core Tools
> Systematic analysis, summarization of data and reporting
> Structured planning and implementation of necessary logistics for transport and loading
> Planning and execution of requalifications (sampling)