Your cost-saving digitazation strategy in just two days

There is no longer any doubt that digitization is the future simply be-cause of its many benefits. This includes shorter throughput times, for example, and lower personnel costs, less production errors, more flexibility and a higher accuracy of delivery dates. However, it is still unclear to many companies how they shape the way to achieve this systematically and with investment security so that they can make the maximum profit from the advantages of digital production.

FELTEN has therefore developed specific consulting services that help to design the individual and risk-free digitization strategy with very limited effort. And in fact on the basis of a solid and reliable calculation of the actual benefit. Because before possible digitization measures are defined, the optimization potentials by a digital mod-ernization of the production are determined in a first, two-day  workshop. Once these advantage perspectives and thus the goal orientation of digitization have been determined, a further workshop, also lasting only two days, will be devoted to the concrete planning of measures to implement the potentials.

The subsequent calculation of the return on investment allows the prioritization of the procedure with the aim of reducing manufac-turing costs in the same year of implementation. This means: With a low consulting effort, you receive your individually tailored, prod-uct-neutral digitization strategy. Of course, both workshops can also be used independently of each other. In addition, a further consult-ing service is available to you. Because our consultants also support you in the successful implementation of the planned digitization measures.

Mastering the digitization of production with investment security

The path to digitization of production processes requires an approach that is not only systematically designed, but also offers a clearly calculable prospect of success in order to avoid investment risks. FELTEN has developed the "Efficiency Booster" roadmap for this purpose. Their idea is that the company will only take the next step towards digitization if there are objectively assured prospects for sustainable efficiency increases. This ensures that the investments are self-financing after just a few months and that the company subsequently benefits permanently from lower expenses. The "Efficiency Booster" process model is based on four steps:

  1. The potential calculation determines which concrete cost savings can be achieved by a realistic optimization through digitization.
  2. Experience benefits live by introducing a quickly implementable entry-level solution of the PILOT software.
  3. Expansion of the pilot process in order to generate a clear and sustainable increase in efficiency from the knowledge gained. It is also advisable to carry out a parallel consulting project to identify and eliminate process weaknesses. 
  4. Flexible extension as required, by successive development of an integrated software landscape. Simultaneous optimization of the relevant processes is recommended.


Detailed information

SAP Production consultancy for a head-start in business

Experience shows that many issues such as production support can be optimized by the SAP System. A central approach brings a consistently high level of transparency of processes, coupled with sophisticated production management for efficient planning and control. Equally it should make timely, situation-based information available to operators, as digitized as possible. In addition, it is essential to create a smooth interoperation between the SAP system for business functions on the one hand and the MES system on the other.

FELTEN is the trusted partner here. Proof of our special skills in production-related SAP optimization comes from over 15 years of experience from many multi-faceted projects for SMEs and DAX companies. This includes process analysis and design as well as project management of international teams in both national and international projects, as well as migration and greenfield deployments. And because we use well-tried Best Practice methods, we achieve our demanding goals without the customary detours; additionally we achieve lower costs despite the higher benefits arising from simultaneous faster project implementations.

Lean integration of MES and ERP/SAP

Integrating production and SAP or ERP systems releases substantial efficiency and profitability capabilities in manufacturing, since you can then work with continuous real-time data. Likewise, the market requirements can be satisfied better with fast and punctual delivery times, because production control can receive timely planning data.  Thus the time is past when lack of integration forces changes which lead to malfunctions, downtime, production losses, quality defects and higher material consumption. But digitization efforts will be supported by integration via the automation of previously manually acquired data. This eliminates administrative tasks and enhances net added-value.

However, an integration between MES and ERP/SAP will be accomplished. FELTEN brings not only its broad wealth of experience competencies, but also its integration consultancy follows a proven, cost-saving methodology. It advances towards the objective, without technical detours and time spent customizing the shop-floor level systems, and for example linking the SAP system for bi-directional relevant data traffic, without, however, compromising on detailed planning. And the results are convincing, even compared against high expectations. Because the Best Practice methods ensure a significantly leaner and far more powerful ERP integration.

For agile and cost-saving logistics processes

Cost-effective and customer-orientated production is closely related to efficient and flexible logistic processes. A modern supply chain management must therefore aim, on the basis of more powerful and also cost-reducing logistics concepts, to reduce stocks and response times, despite fluctuations in volume or quantity.

Certainly a company-wide approach ensures that delivery times decrease, bottlenecks are eliminated and higher customer satisfaction ensues. High-quality supply chains are characterized by being lean and agile, and integrate the entire processes from the supplier via the production company through to the customer.

Here the conceptual skills and wide practical knowledge of FELTEN consultants are needed. They use tried and tested methods for intelligent supply chain management, achieving sustainable process improvements with higher delivery reliability and lower cost conditions through their innovative and digital focus. They assist in the systematic process analysis to identify optimization and flexibility capabilities, as well as the conceptual planning of procurement, production, order processing and distribution processes and process implementation.

How to: Process optimization

The true potential to increase the performance level and economic performance lies hidden within the production processes. And weaknesses in the process quality show, for example, in excessive demands on human and machine resources, idle times, unplanned downtime, poor quality and high materials wastage. Moreover, overproduction, excess inventories, over-long transport routes, high latency or imprecise delivery dates are also usually the result of poor procedures.

And those weaknesses are by no means the manufacturing enterprises. The background to this is that many production processes consist of not just a single production step but rather a number of consecutive production stages. In such complex manufacturing systems, the number of input parameters to be considered, control information and irregularities are extremely high.

The consequence is that the causes of problem and stoppage conditions must be systematically identified to bring in the required optimization knowledge and to be able to achieve quantifiable benefits. Such a role, from the analysis of states and benchmarks through to optimized process modelling, is particularly suited to FELTEN.  

OEE and more key data for process control

Performance management in production is only possible where there is a continuous high level of transparency. This requires precise monitoring of the processes, and such production control necessitates demand-based tailored key data. However, many production enterprises are still a long way from this position.

According to a recent FELTEN study, three in five companies lack the technical capability and the analytical experience to measure production performance levels and to evaluate optimization measures. Similarly there is a lack of appropriate measurement systems. Even well-established key data methods such as OEE (Overall Equipment Effectiveness) are still not widely prevalent.

Our answer: FELTEN’s tailored optimization consultancy, which comprehensively captures the existing production process conditions and takes the key data management to a new level, with high additional benefits. This can cover all areas from production costs to efficiency / productivity, maintenance and quality to production reliability and sustainability, following customer-tailored requirements. For this we use excellent Best Practice methods and broad experience and knowledge: where necessary we also use our PILOT:OEE software solution.

Planning Industry 4.0 properly

Many production managers view the subject of Industry 4.0 as an exciting prospect and specifically associate it with benefits such as greater automation in production, the capability to produce personalized products, as well as commercial benefits and new competitive opportunities. But Industry 4.0 does not conceal a project where the production structure has suddenly changed fundamentally. Instead, it hides a path to the future, already in progress.

In fact many companies are already involved in this area, even if these projects are not explicitly labelled “Industry 4.0”. It is noticeable that, for example, increased investments are being made in MES infrastructures with ERP integration, standardized production processes and the analysis of process data for efficient production control.  Thus important preconditions are being fulfilled, as Industry 4.0 requires that real-time data from the periphery are produced regarding production times, machine utilization, personnel resources, material and energy usage, and more.

This is one foundation of the future intelligent Industry 4.0 production, but it still does not fully cover all aspects of the subject. It is necessary to plan the route forward strategically, and to create a systematic development process: FELTEN, as a consultancy partner, fully understands this.