Production Improvement Consultant (LEAN)

Consultant / sparring partner / trainer / project manager / interim manager reducing production problems together with leaders and skilled workers.

I am usually on site 2-4 days/week for several months. I analyze and assess the current situation, develop improvement proposals, bring them to a decision and support/drive their implementation. When needed, I train participants in LEAN / AGILE (mindset and methods). I work iteratively and align the approach with management.

The collaboration becomes safer, more pleasant and more effective. The output and quality improve. Overall, processes become more efficient. Managers spend less time troubleshooting and have more time again for their proactive leadership tasks.

Process improvement -> Standards & CIP; workflows of people & machines in assembly, logistics, manufacturing, quality management, administration; value stream analysis; flow; takt & cycle times; lead times; PULL instead of push; material provisioning; material transport; replenishment / Kanban; inventories; supermarket design; OEE/GAE; TPP/GAB; tool management; JIS/JIT; product quality; process quality / JIDOKA; shopfloor management; Six Sigma; operational excellence; etc.

Technical product design -> manufacturability; transportability; assemblability; customer value; customer satisfaction; prototypes; etc.

People development -> skills; behavior; values; collaboration; leadership; organization; cooperation; project work; etc.

• Train-the-trainer for TOS consultants in 3-month projects in global production & administration
• Coach for leaders
• Instructor in various LEAN trainings
• Continuous improvement of global operation standards, project templates and analysis tools for TOS/LEAN

• One-year training in theory & practice
• Independently carrying out projects to stabilize & streamline various processes in stamping, body shop, painting, manufacturing, assembly, logistics and maintenance
• Design and instructor in trainings
• Coaching of leaders, employees and teams in behavior, collaboration and strategies

• Operational issue management
• Set-up of integrated KPI system and shop floor management
• Co-design of Mercedes-Benz Production System (MPS) based on Toyota's TPS

• Partly alongside studies: assembly of electric motors for remote-controlled model building
• Set-up and optimization of work processes
• Design of components for RC cars and production machinery