Lean Production

We’ll help you to achieve an effective and Lean production.

Lean and digitization go hand in hand

The term Lean production combines a wide variety of methods and approaches to minimize waste in production, leading to Lean production. After the emergence of the Lean idea in the 1990s, waste-free production is still pursued by all successful companies today.

The next step after Lean towards improved and waste-free processes is the digital business transformation of the processes, which enables optimal coordination of all areas. The step from Lean to digitization is also known as Lean 4.0, but an already Lean production is the prerequisite for Lean 4.0.

Inefficient, undefined or slow processes can only be optimized to a limited extent by digitization, according to the motto: „If you digitize a bad process, then you have a bad digital process.“ Whereas processes that have already been coordinated can exploit the full optimization potential of digitization.

The Lean philosophy

The Lean philosophy follows the approach of a holistic, continuous process optimization and includes the efficient design of the entire value chain. The goal of a „Lean company“ is pursued using a wide variety of methods, principles and procedures.

Customer orientation and cost reduction are the central aspects of the Lean philosophy. Recognizing and eliminating waste potential in all corporate processes means integrating all areas and their interaction towards the joint, loss-free satisfaction of customer needs.

It is not only necessary for all areas to work together, but also across all levels. The technical equipment, the commitment of the management level and the involvement of the employees are representative of the multi-dimensionality of the Lean philosophy. 

The most common reasons for Lean production

All reasons for the introduction of Lean production are based on customer orientation.
By introducing Lean, you can:

  • Long response times and thus long waiting times for the customer are reduced
  • Quality problems are avoided, and customer complaints are reduced
  • The production costs can be reduced by avoiding waste
Why does Lean fail?

The introduction of Lean for the sake of the lean trend is doomed to failure from the start. The introduction of Lean means a change in the corporate culture and the involvement of all employees in the Lean concept.

Many Lean projects fail due to half-hearted implementations of generic lean methods that have not been adapted to the company’s own requirements. Placing unused, colourful Lean Boards in production and seeing Lean training courses as costs instead of investments hinders a successful Lean introduction and thus continuous improvement in the company.

The Lean idea must be actively supported by the management and conveyed to the shop floor because only here do new methods have an effect. The Lean concept must be anchored in the minds of all employees in order to quickly identify and eliminate waste.

We provide a new push towards Lean. We bring a comprehensive set of methods and experience in implementation. In addition, we see ourselves as an activator who, in on-site workshops with the workers and managers, brings motivation to the scene and strengthens your shop floor management. Our range of services also covers the digitization of production so that the potential for Lean 4.0 is taken into account. With us, you will find the right combination of method set, inspiration and innovation.

Structured to Lean success with ifp consulting

A wide variety of different Lean methods have been developed over the years. The classics are classified in the graphic according to the complexity and implementation period. In order to guarantee the long-term implementation of these methods, however, holistic approaches that encompass the entire company structure and break down the company’s goals into the individual areas and employees should ideally be stored upstream. These approaches include, for example, Hoshin Kanri or Charter Thinking.

ifp USP

Induce attitude change
Quick-win projects as an initiator for empowerment

SMED workshops
Process analysis and joint optimization together with the employees

Production and material flow simulation
Identifying and minimizing waste

Lean 4.0

Lean 4.0
Preparation for digital conversion based on Lean processes

Shop floor management

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