• Actions and measures plan as an information basis for better awareness in all employees
• Short Interval Management / SIM for convenient and time-saving communications between all operators and management staff
• Determination of overall plant efficiency (OEE) with manual or automatic fault detection for systematic efficiency improvements
• Statistical Controls with statistical evaluation of operating- and quality data
• All events in a shift are recorded in a system and made available to the follow-on shift
• Use of Value Stream Mapping for data capture and display

Decreasing batch sizes and thus more frequent format and product changes generate higher error rates and lead to increases in production cost. Unexpected technical defects cause delays, fluctuating material quality brings reworks, write-offs and more production cost increases.

Lean Management typically aims to reduce costs, improve quality and complete customer orders on time and to the correct amount, as well as identifying wastage and losses, locating potential improvements and enhancing production processes with the appropriate solutions and methods. This brings reduced throughput times, higher quality levels and sparkling cost reductions. Companies employing the Lean approach do in fact often achieve a doubling in production capacity and cut delivery times by half, using fewer resources.

Effective Lean Management also requires modern, future-proofed system support. PILOT:LEAN includes well-established and familiar Lean methods and tools, including amongst others Value Stream Mapping, for capability-oriented evaluation of production processes. A further advantage of the system is that the classifications used guide employees in a more convenient, targeted way. This results in a uniform approach and processing of capabilities without administrative overheads, regardless of whether there is already Lean methodology knowledge at the site.