Initial situation and objective
• There were high additional costs involved for warehousing and order picking .
• Efficiency losses and ergonomic deficiencies were visible in the production processes due to the workplace situation .
• The processes were paper-based and required a lot of documentation .
• Space was not used efficiently , which meant there was a lack of space .
Procedure
• In the first step , a value stream analysis was carried out and the optimization potential was identified and evaluated .
• A 5S workshop with employees increased awareness of the need for change and the concept of lean methods .
• The workstations were then conceptualized in the cardboard workshop , after which the joint implementation of the developed solutions got underway very quickly .
Results of process optimization
Increased efficiency and productivity The production documents were converted from paper to digital documents . The provision of materials was organized according to the production process to reduce walking and reaching distances . By restructuring the work environment in accordance with the 5S method , it was possible to significantly reduce the amount of space required .
Sustainable process optimization The roadmap designed with work packages enabled the step-by-step and sustainable optimization of processes .
Satisfaction of employees The entire workforce was first trained on the 5S methodology in workshops . Employees then worked on the workstation design in three teams .
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