At the core of every value chain system lies production in its many forms – with regard to individual companies as well as complete production networks. Our aim is to strengthen the success of your company through conception, design and optimization of production structures and processes both on planning and operational levels.

DESIGN OF PRODUCTION SYSTEMS

Flow systems: A “flow” production does not necessarily need a tightly sequenced production line. Instead, our conceptual focus lies on ensuring  smooth production processes without disturbances and waiting times, while allowing an efficient inclusion of a large number of product variants. The minimization of lead and cycle times demands not only an efficient but also a flexible system. Fluctuations with respect to time and capacity requirements are an essential part of the planning procedure to ensure an accurate depiction of the available framework

Production systems: The configuration and design of inter- as well as intra-company production networks poses substantial challenges at the operational level. We not only possess technical expertise to conceptualize and implement effective production networks, but also have the know-how to define suitable leadership processes along with monitoring and management instruments.

DESIGN OF DEVELOPMENT PROCESSES

The minimization of lead times and costs becomes increasingly complicated if the product design hinders the optimization of production and logistic processes. A systematic integration of manufacturing technologies, supply strategies and logistic structures into the product development process enables a greater room for manoeuvre for the design of the operational structures and processes.

This is secured by structuring the product development process in a manner that allows thorough transparency about the status of the development as well as the degree of fulfilment of the project targets with respect to performance and financial indicators. Other imperative aspects to ensure a robust construct include the definition of the organization and the implementation of controlling instruments.

QUALITY-INTEGRATED PRODUCTION

Strive to avoid defects, not correct them: The optimization of quality by correcting detected defects at the end of production processes not only leads to higher costs, but also increases the process complexity and lead times. Process excellence as the INSTITUTE FOR MANAGEMENT EXCELLENCE (IMX) understands it dictates that the predetermined quality standards have to be met at the completion of each production step so that defects are not transferred into the next process step.

There are several ways to achieve this goal, including process-integrated methods such as Poka-Yoke, intelligent automation as well as technical and organizational monitoring methods to uncover quality defects as early as possible. In order to provide support for the management, this process design is complemented by methods and tools, such as KPI-cockpits, escalation measures or instruments that enable speedy and collaborative problem-solving.

PRODUCTION OPTIMIZATION – FLEAN MANAGEMENT

The basis of sustainable value addition are efficient, customer-oriented processes. Our aim is to firstly discover disorders and inefficiencies and finally to eliminate them, which we achieve by combining quantitative methodology with practical know-how and experience gained from numerous successfully conducted projects. We consequently follow the philosophies of LEAN Production, supplementing them with methods to ensure the required flexibility in cases of customer demand fluctuations, employee qualification programs and technical stability issues. The choice of methods is adapted to the assignment and these encompass a wide array of optimization techniques such as 5S, structuring of work areas and the long-term securing of success through audits.

PRODUCTIVITY MANAGEMENT

For IMX, the monitoring and improvement of productivity involves the relation between material and personnel costs and output. For examining target deviations – derived from plans and benchmarks – we apply quantitative analytical methods based on the production processes at hand. Process design, supplier management and support by means of constructive optimizations are the foundations to increase productivity in the long-term.

SHOPFLOOR MANAGEMENT

An efficient target achievement on the shop floor requires the definition and monitoring of structural and process standards. It is imperative to determine duties, competencies and responsibilities as well as to set regular meetings to discuss progress. In addition, it is important to extract and deliver relevant data for process management and decision-making support. For this purpose, simple visual tools such as markings, pictograms, barriers and display boards can be utilized or technically advanced instruments such as tablets for foremen displaying real-time information can be installed. The core of these activities is the design of management and value addition processes for achieving company targets.

LAUNCH MANAGEMENT

Irrespective of detailed preparations, the launch of a new or modified product poses a challenge for the production system. Processes that have been devised in a laboratory environment must also function in real manufacturing conditions. Uncertainties and disturbances can arise particularly at interface points. The production readiness audits of IMX can reveal potential sources of disturbance at an early stage, which helps support the management of pre-series processes. The experienced consultants at IMX provide guidance during the operational launch phase and contribute proven instruments for the monitoring and control of the entire process.