Complexity management in the machinery and plant construction sector
Machinery and plant construction companies often have internationally oriented value creation networks in which they must react flexibly to customer requirements. The diversity of products, processes and markets confronts them with a high degree of complexity.
Effective complexity management strengthens
efficiency as well as innovation and competitiveness.
ROI-EFESO enables companies in the machinery and plant construction industry to identify complexity drivers along their entire value chain. In order to reduce complexity, they are testing the design of their Product portfolio. We also develop standardized processes and structures for the entire value chain together.
Results
In complexity management projects, companies work with ROI-EFESO to pursue various objectives such as cost control or freeing up resources for innovation. In the context of industry-specific challenges, they realize the following results (selection):
- 15% - 25% Shortening the development time through modular product development
- 10% - 20% Reduction of assemblies p.a. through modularization
- + 2 - 10 Increase EBIT margin
Success factors for complexity management in machinery and plant construction
When working with ROI-EFESO, companies focus on the following fields of action:
- Portfolio reduction: reassessment of the Product portfolio with regard to the complexity costs of individual products and their actual market attractiveness.
- Platform strategy / modularization: development of standardized modules that can be flexibly combined and thus allow a greater variety of variants at controlled costs.
- Process harmonization: structuring and standardization of processes in different departments, plants, locations, and companies, e.g. in the context of post-merger integrations.
- Cultural change & leadership: creating the framework conditions to lead transformation projects to success, from the shop floor to management; anchoring new cultural practices and monitoring the progress of change.
Further services for companies in the machinery and plant construction industry
CLIENTS
CASE STUDIES - PRACTICAL EXAMPLES
OPEX: Worldwide Operational Excellence Initiative
The ROI-EFESO OPEX model: activate the forces of excellence. You learn from mistakes. It is important that continuous improvement is the result. In industry, this is targeted as "Operational Excellence", or OPEX for short. Instead of resorting to off-the-shelf solutions, companies should develop their own strategies here - like the group from the steel industry, which successfully used the OPEX model from ROI-EFESO in its plants.
Cost reduction/restructuring due to market changes
A plant and mechanical engineering company had to ensure its competitiveness. ROI-EFESO identified all the adjustment screws for the necessary changes at a production site in Germany and got the turnaround going with a multi-layered restructuring approach.
Reduction of complexity through standardization
In China, the "made in Germany" label stands for innovative strength, quality and a high level of development competence on the part of the manufacturers. A textile machine manufacturer wanted to reduce the variance and complexity within the Product portfolio. The main goals: reducing costs and strengthening the position in the Chinese market. With the China expertise of ROI-EFESO, a solid, regional supplier network was created in a short time.
Digital Process Twin: Process optimization through Predictive Quality and Predictive Production
An automotive supplier improved the transparency of work and organizational processes in a production plant for dashboards. With a "Digital Process Twin" from ROI-EFESO, the company reduced the reject rate and made improvement potentials in its value creation networks visible.
Lean Digital Manager
Shaping the factory of the future with Lean 4.0. How can lean principles be combined with the technologies and possibilities of networked digitization in value creation networks? By further qualifying employees to become decision-makers. The ROI-EFESO certification program for "Lean Digital Manager" shows how digitalization of lean production works. To do this, it combines strategies with Industry 4.0 technologies.
Operations Footprint: Redesign of the worldwide manufacturing network
Reorganization of the manufacturing landscape: A manufacturer of industrial pumps is pursuing the goal of achieving a new sales growth record within three years. With ROI-EFESO, the mechanical engineering company therefore put the manufacturing footprint of eight locations and subsidiaries in its international production network to the test. Among other things, it analyzed the product groups and segmented the manufacturing landscape.
Energy boost for the SAP S/4HANA transformation
A mechanical engineering company wants to activate the digital innovation potential at its global locations by switching from SAP R/3 to SAP S/4HANA. Together with ROI-EFESO, it revitalized an ERP / MES transformation that had previously been started with another service provider and threatened to lead to a costly dead end.