Lean Logistics Consultancy

Value Stream Analysis and Potential Identification

Identifying waste (Muda) forms the basis of our consulting services, where we use value stream mapping to uncover opaque material flows and process gaps. We analyze your processes in detail to systematically eliminate waiting times, redundant handling steps, and unnecessary transport routes. This methodical assessment allows us to precisely quantify optimization potential across your entire supply chain.

Planning of consumption-driven pull systems

We implement the pull principle based on customer demand to ensure a consistently consumption-driven supply without overproduction or unnecessary inventory. In doing so, we develop standardized supply concepts such as Kanban systems, supermarkets, or demand-driven sequencing for your workstations. This approach significantly reduces supply lead times and enables your company to respond agilely to market fluctuations.

Engineering and vendor-neutral technology selection

Drawing on our deep engineering expertise, we plan and design the necessary logistics spaces and select the optimal transport and handling equipment for your needs in a vendor-neutral manner. We support you in specifying and tendering for tugger trains, automated guided vehicles (AGVs), and automated material staging systems. Our focus is on technological integration, ensuring that the selected hardware fits seamlessly into your existing process landscape.

Digital transformation of material flows

We create a digital database for your planning and use tools such as KNIME or Tableau to visualize complex data streams. Using sensors and actuators, we support the control of your processes and make material flows transparent for your management decisions via dashboards. This digital support ensures the future viability of your lean strategy and enables data-driven performance monitoring using relevant KPIs.

At ebp-consulting, we are the ideal partner for companies looking for practical results at the point of value creation, rather than theoretical concepts. We combine strategic foresight with technical expertise to sustainably reduce your logistics costs by eliminating empty runs and process bottlenecks..

Our advantages at a glance:

• Strict vendor independence: As a neutral partner to our clients, we guarantee objective technology recommendations without the risk of vendor lock-in.
• Fraunhofer DNA: Our roots in cutting-edge applied research ensure scientifically validated methods and the highest level of methodological excellence..
• Strong Operational Execution: We only plan what we can demonstrably deliver based on our 20 years of experience and 4PL expertise.
• Big Data Analytics: By using specialized tools such as Log-hub, we achieve a depth of analysis that goes beyond conventional consulting approaches.

Our hybrid model combining consultancy and operational support gives you the assurance that we are personally committed to the success of our concepts. With ebp consulting, you are investing in the resilience of your supply chain and regaining the flexibility that determines your competitiveness in today’s market environment.

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Our approach is characterized by a holistic, pragmatic, and collaborative methodology that places customer value at the heart of every initiative. We bridge the gap from SCM strategy through material flow design to IT system selection (WMS/TMS) to consistently avoid system disconnects. In doing so, we use scientifically validated methods such as MTM analyses or simulation models to rule out planning errors early on and ensure operational stability even before implementation.

To guarantee this standard from the initial analysis through to a successful go-live, we combine our expertise and methods into four structured service phases:

1. Data-driven analysis and value stream design

The key to robust logistics planning is creating complete data transparency through the systematic identification and assessment of opportunities for optimization. Using value stream mapping, we make invisible material flows and hidden waste along the entire value chain visible and measurable.

Components of data-driven analysis & value stream design:

• Value Stream Mapping: Systematic recording and identification of optimisation potential along the value chain.
• Logistics volume framework: Establishment of a digital database for the planning of logistics space and processes (for all relevant materials and products).

Building on this, we create a detailed logistics volume framework that precisely records all relevant materials, parts and products, as well as their specific requirements for logistics processes. This robust, digital database then serves as a reliable foundation for the fact-based planning of future logistics space and material flows.

2. Process design and layout planning

During this stage, we design material flows with the goal of achieving maximum flexibility and space efficiency by implementing a consistent pull system precisely aligned with the customer’s production cycle. We develop standardized supply concepts, which we structure using the line-back approach for manufacturing companies and the shelf-back approach for retail companies.

Process design & layout planning:

• Pull principle & customer-driven rhythm: Implementation of a consistently consumption-driven logistics system.
• Standardized concepts: Development of material flow concepts based on the line-back approach (manufacturing) or the shelf-back approach (retail).
• Workplace-based provision: Design of direct supply (production cell/line) incorporating supermarkets, Kanban, sequencing, portioning, and kitting, as well as 5S.
• Sizing & Visualization: Determination of logistics areas, creation of layouts, and use of Sankey diagrams to optimize internal material flows.

Workstation-based direct supply is designed in detail for each production cell or assembly line using tailored methods such as supermarkets, Kanban, sequencing, portioning, kitting and 5S principles. To clearly visualise and optimise these in-plant processes, we use Sankey diagrams, on the basis of which we create the specific layouts and precisely dimension the necessary handling areas.

3. Resource, equipment and technology planning

To ensure the optimal use of your resources, we determine the exact hardware and personnel resources required based on the previously defined, waste-free processes. We identify and plan the most suitable equipment, ranging from bespoke in-house containers and floor rollers (E, U, T and B frames) to highly automated driverless transport systems (AGVs).

Components of resource, equipment & technology planning:

• Transport and handling equipment: Identification of suitable forklift systems, tugger trains, floor rollers (E/U/T/B-frames) and automated AGV systems.
• Container management: Development of optimised in-house container concepts.
• Staffing requirements analysis: Precise calculation of resources for logistics processes using MTM and REFA..
• Digital integration: Support for material flow through automation, sensor technology and actuators for control via dashboards.

At the same time, we objectively and precisely calculate the actual staffing requirements for all relevant logistics processes using scientifically validated methods such as MTM and REFA. Finally, we integrate digital solutions such as sensors, actuators, and dashboards to optimally support the automated equipment and enable real-time control of the material flow.

4. Procurement, implementation and control

We don’t stop at theoretical planning; through comprehensive project management, we take responsibility for ensuring a smooth transition to a fully operational system. When procuring the necessary equipment—such as tugger trains, AGVs, handling devices, and racking systems—we provide impartial support, from detailed specifications through the bidding process to the final selection.

Components of procurement, implementation and management:

• Tender management: Support with the specification, selection and procurement of equipment (tugger trains, AGVs, racking, etc.).
• Performance management: Development and introduction of meaningful logistics key performance indicators (KPIs).
• Implementation: Holistic project management and active support throughout implementation.

To ensure that operational performance can be objectively measured following implementation, we simultaneously establish a system of meaningful logistics metrics. Through our active support during implementation, we ultimately ensure that the designed processes run smoothly from the outset and become firmly embedded in your day-to-day operations.