What do I need a manufacturing flow chart for?

hologram illustration of a flow diagram in process planning

Flow charts and various process flow diagrams (PFD) fill countless pages in quality management manuals. All too often, they are smiled at as management wallpaper, and almost everyone knows that things work differently in practice anyway than they are theoretically painted on the brown paper in the production manager’s office. But where does the desire … Read more

How to organize factory layout planning?

Anyone who is responsible for production, logistics, or IE in their organization may already have experienced that end-to-end layout planning in 3D still seems problematic despite the companies’ extensive digitization activities. Indeed, these and comparable technical aspects must be taken into account. Nevertheless, they could distract from organizational necessities. After all, functioning systems consist not … Read more

Avoid material handling costs

Illustration der Kosten für Materialtransporte mittels Gabelstapler in einer Fabrik

Regarding material handling in the industry, thoughts quickly turn to logistical equipment and the associated optimization issues. But hasn’t the proverbial baby already fallen into the well when aspects of logistical solutions come into focus? After all, logistical requirements are preceded by their causes. Those who know them and work on them consistently will also … Read more

The plant floor plan – just a drawing?

Manager überlegt zum Fabriklayout

Of course, the questioning title of this blog is rhetorical. Because in recent decades, both the way plant floor plans are created and their potential benefits have changed considerably. The reason for this – you guessed it – is the developments in IT and digitization. The impact of digitization on plant floor plans If we … Read more

Strategic thinking

strategic thinking skills and planning steps

The ability to align strategic decisions with a long-term philosophy If you are looking for the best strategy for a company, you quickly end up with Toyota’s policy. The “Toyota Way” has not only become a bestseller, but also a buzzword for strategic decision-making – a role model, and not just for large companies. Read … Read more

AGV vs. Tugger train

illustration of race between tugger train and agv

AGVs (automated guided vehicles) are also on everyone’s lips when it comes to forward-looking logistics concepts. Driverless is often seen as the next, higher goal after forkliftless. In lean management, however, tugger trains are the means of choice. Are AGVs now making tugger trains obsolete? In terms of transport history, the development in the 20th … Read more

Planning an assembly line – 5 key aspects

Assembly line planning one-piece-flow example

Assembly lines within one-piece-flow (OPF work systems) are very popular in assembly planning. Great advantages are associated with this in lean production. In this context, particular mention should be made of the following: Short lead times, low inventories, good possibilities of automation also with the use of (collaborating) robots, continuous production and last but not … Read more

Restructuring: Merge Value Stream and manufacturing layout!

The integration of value stream and layout in a digital factory model is a decisive competitive advantage in the restructuring of manufacturing sites.

Very many, if not most, planning projects in industry involve restructuring the manufacturing site: So space for manufacturing is needed somewhere, and often there is even space available somewhere else in the facility. If the new asset fits where the old equipment is moving, replacing it quickly appears to be the most practical and cost-effective … Read more

The TOP 5 Lean Production Methods for factory planning

Planerin bedient Touchbildschirm Prozessplanung mit logix in der Software visTABLE

Lean production methods and lean management traditionally focus on continuous improvement (KAIZEN). Many lean methods therefore logically focus on discovering waste in existing processes. In this way, they trigger the continuous improvement process in the company. In factory planning, on the other hand, completely new productions are created on the drawing board. Innovative processes are … Read more