Operations assessment and measures roadmap
How could we help?
Our customer, the RECKLI GmbH is an internationally active manufacturer of high-quality textured formliners for architectural and concrete surfaces with a high degree of vertical integration – from raw materials to mould construction and matrix production.
Changes in the customer base and product portfolio have led to increasing complexity in order processing and production in recent years, without processes, systems and control logics being adapted accordingly.
We were able to support RECKLI with an operations assessment with process simulation and in the development of a realistic target picture and a roadmap until 2027 with measures for operations optimization.
The task:
The aim of the project was to carry out a transparent assessment of current performance together with the RECKLI project team, identify key weaknesses and develop a clear target picture including a roadmap for a sustainable operations excellence transformation.
What have we achieved?
In the focus: key figures and results
Customer testimonial Reckli
Our contribution
Problem
The analysis revealed room for improvement along the entire value chain. In particular, there was a lack of consistent standards for recording and passing on information, clear roles and responsibilities as well as reliable KPIs for process control.
In addition, media disruptions, manual planning steps and a lack of system support made efficient order processing more difficult. In production, long throughput times, a high proportion of non-value-adding tasks and ergonomically unfavorable activities led to inefficiencies and stress for employees.
Challenges
These challenges were deliberately addressed and used as a lever for sustainable improvement.
Approach and methodology
ifp consulting relied on a structured, practical methodology that consistently combines analysis, transparency and feasibility. In the first step, an Operations Excellence Performance Assessment was carried out, consisting of plant inspections, interviews, data analyses and a systematic performance check along 15 categories – from production and logistics to management, KPIs and IT. This was followed by an end-to-end process simulation of order processing, in which information and material flows were recorded in detail, evaluated and analyzed in terms of effectiveness and efficiency. Central pain points were transferred into four overarching fields of action:
In workshops with the specialist departments, ifp consulting worked with RECKLI to develop a target picture and a concrete roadmap up to 2027, including prioritized measures, responsibilities and timelines. The methodology was characterized in particular by a high level of involvement of the organization, transparency of the results and a clear implementation logic.
The solution:
The project created a reliable basis for decision-making for the transformation of order processing and production at RECKLI. The key results are a clear target image, defined fields of action and a roadmap with concrete measures such as the introduction of a KPI system, the standardization of information recording via a parameter sheet and the optimization of stock transfer and production processes.
Result and outlook
Sustainable increase in productivity
The planned digitalization, improved governance structures and the systematic establishment of a continuous improvement process (CIP) will enable RECKLI to control processes based on data, reduce throughput times and sustainably increase productivity. At the same time, ergonomic improvements and qualification measures were anchored as fixed components of the solution.
In the next steps, RECKLI will start the consistent implementation of the roadmap, accompanied by a structured Project Management Office (PMO). ifp consulting will continue to support the implementation of selected measures.
The aim is to anchor the structures developed in the company in the long term and to gradually develop the organization in the direction of digital, efficient and future-proof production.
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How we can optimize your processes
Our team of seasoned professionals brings decades of experience in production and logistics optimization. By partnering with ifp consulting, you gain access to industry-leading insights, methods, tools and technologies that deliver immediate and tangible improvements. Contact us now to make the transformation and optimization of your processes a success!
