Management of Production Consulting

The Importance of Production Planning in Supply Chain Management

Production planning is the operational heart of the supply chain and operates precisely at the interface between customer demand and physical manufacturing. Across all sectors, it is indispensable for manufacturing companies – from car manufacturers to medical technology firms – in order to reduce set-up times and establish lean value creation. The measurable benefits of optimisation are evident in drastically reduced lead times, minimised capital tied up in inventory and a sustainable reduction in the ‘cost to produce’. As a reliable partner, ebp-consulting GmbH ensures a decisive competitive advantage through data-driven approaches such as lean production and digital system integration.

Enquire about production planning

‘Production planning is not just about synchronising machines, but about the seamless coordination of materials, people and methods – for a supply chain that works rather than grinding to a halt.’

Kasra Nayabi
Managing Partner at ebp-consulting

Our key focus areas in production planning

To achieve operational excellence, selected core areas of production must be systematically and uncompromisingly rethought. These strategic and operational priorities are essential to any sustainable process restructuring if the full potential for value creation is to be realised. Drawing on years of consultancy experience, ebp-consulting has identified six fundamental focus areas that serve as reliable levers for maximising efficiency.

Areas of our management consultancy in production

Production strategies
Production Planning & Scheduling
Production logistics planning
Lean production
Enhancement of machine utilisation (OEE optimisation)

Optimisation of retooling, SMED/quick changeover

Implementation of value stream analysis and design

Introduction of flow manufacturing (one-piece flow)

Implementation of Toyota production principles: One-piece flow, pull principal, zero defects, clocked production

Application of lean methods/techniques Poka yoke, jidoka, minomi, chaku chaku

Application and implementation of Six Sigma
Assembly planning
MTM analyses in Production

Logistics consulting in Stuttgart, Munich and Dortmund

Challenges in production planning

In practice, established but historically outdated production structures often clash with changing production volumes and an increasingly complex product range. This inevitably leads to high stock levels, extremely long lead times and constant, inefficient rescheduling on the shop floor. Furthermore, isolated planning silos hamper the smooth supply of materials and prevent transparent, cross-departmental coordination. This is precisely where ebp-consulting GmbH steps in, using its in-depth expertise and bespoke solutions to systematically transform these hurdles into competitive advantages.

Inherent inefficiencies and outdated structures

Many companies operate with production facilities and layouts that no longer meet today’s flexible market requirements. The result is excessive lead times and unnecessary capital tied up in massive excess stock. ebp-consulting resolves these structural bottlenecks by replacing outdated systems with agile, waste-free layouts.

Complex material supply and a lack of transparency

Production rhythms tend to falter when material supply is not precisely aligned with production control. This creates buffers that take up space and cost money, whilst valuable machinery remains idle unplanned. With ebp-consulting’s intelligent logistics interfaces, these inefficiencies can be eliminated and a genuine, transparent pull effect established.

Lack of data integration and planning silos

In many organisations, production, procurement and sales operate in isolation, making robust, integrated capacity planning virtually impossible. This results in massive discrepancies between the target plan and actual performance on the shop floor. Through ebp-consulting’s data-driven strategies, these silos are broken down and well-founded solutions for a seamless Sales & Operations Planning (S&OP) structure are implemented.

Approach to production optimisation with ebp-consulting

ebp-consulting’s approach is characterised by a precise integration of sound logistics theory and the practical realities of the shop floor. We work in partnership with our clients from the initial concept right through to the final, measurable implementation of the optimised processes. This methodical yet practical approach maximises planning reliability and significantly reduces the risk of costly errors.

1. Status Quo Analysis and Definition of Objectives

In the first step, ebp-consulting conducts a detailed analysis of existing production structures to identify hidden capacity drainers and process breaks. In doing so, we collect the actual master data directly on the shop floor, which makes our approach particularly realistic, robust and unbiased. On this fact-based foundation, we work with the client to formulate clear, strategic objectives for reducing lead times, which the ebp team then consistently implements.

2. Development of bespoke production concepts

Based on the analysis results, we design integrated production and logistics strategies that are precisely tailored to specific market requirements. What sets the ebp approach apart from traditional consultancy here is the uncompromising integration of material flow issues with PPS methodologies, all from a single source. Instead of drawing isolated layouts, we simulate takt time and the value stream holistically within a fully integrated process. This guarantees smooth control and closes theoretical planning gaps before they can arise in practice.

3. System selection and digitalisation

We provide vendor-neutral support in the selection and integration of modern planning software and future-proof IoT solutions. ebp-consulting does not view digitalisation as merely an end in itself, but as a digital enabler for waste-free, highly profitable lean processes. We set ourselves apart by ensuring that the software architecture always follows the optimised physical reality of the process, and not the other way round. This creates targeted automation that keeps the production network agile, flexible and extremely efficient.

4. Implementation and Continuous Monitoring

During the crucial implementation phase, ebp-consulting takes genuine responsibility and manages the change process directly on the shop floor. Unlike many competitors, we do not leave the project once the concept has been handed over, but provide intensive coaching to staff. We establish continuous improvement cycles (CIC) and Kaizen routines that ensure the long-term success of the agreed measures. This guarantees that the operational excellence implemented remains deeply and sustainably embedded within the organisation.

Areas of focus and sub-areas of production planning

Production strategies and S&OP

This area of focus synchronises sales demand forecasts with operational production capacity to create cross-departmental transparency. High-performance APS tools that harmonise push logic with agile pull principles are well-suited to implementation. A key benefit is the reduction in ‘cost-to-produce’ through the early prevention of bottlenecks.

Assembly Planning and MTM Analyses

The precise design of assembly areas aims to minimise throughput times through ergonomic and route-optimised layouts. By using standardised MTM tools, companies can accurately calculate and increase efficiency at workstations. Reducing set-up times and directly involving employees are among the most important levers here.

Production Logistics and Lean Management

This sub-area focuses on demand-driven sequencing of material supply, from intralogistics right through to the production line. Systems such as Kanban enable a significant reduction in circulating stock and the achievement of stable sequencing. Companies benefit from intelligent pull strategies that eliminate waste and ensure the highest level of delivery reliability.

Production Planning and Production Control

Production Planning and Scheduling (PPS) forms the operational backbone of manufacturing by precisely translating customer requirements into material and capacity plans synchronised with production. Through the use of advanced Advanced Planning & Scheduling (APS) systems and agile Kanban mechanisms, lead times can be minimised and changeover costs drastically reduced. To ensure a successful system implementation, we recommend systematically cleaning up historically accumulated ERP master data and aligning planning cycles uncompromisingly with a consistent Sales & Operations Planning (S&OP) approach.

Insight in current topics

Production control strategies to reduce throughput times

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Operational excellence in assembly through implementation of lean manufacturing

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Adaptation of production strategies during factory expansion

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Achieving excellence in Production Planning: Your project options with ebp-consulting

Holistic Consultancy Project (End-to-End)

With this turnkey approach, we support you from in-depth value stream analysis right through to the full implementation of the new architecture on the shop floor. You benefit from an integrated, one-stop solution in which material flow, layout and systems are perfectly coordinated. This minimises interface losses and guarantees a smooth go-live with an excellent return on investment.

Flexible Deployment of Experts / Interim Management

In the event of short-term resource bottlenecks or complex special projects, we provide you with highly qualified logistics experts. They bring in-depth methodological expertise directly into your organisation and are operationally effective from day one. This enables you to bridge staffing gaps professionally and keep your restructuring projects firmly on track.

Strategic Quick-Check / On-site Audit

This standardised audit identifies the biggest inefficiencies and hidden bottlenecks in your production within a very short time. You receive a pragmatic assessment of your processes as well as a clear roadmap with quick wins that can be implemented immediately. This compact check-up is the ideal, low-risk starting point for identifying potential improvements without high initial investment.

Your collaboration with ebp-consulting

A partnership-based collaboration with ebp-consulting guarantees you not only strategically sound concepts, but also measurable efficiency gains and future-proof processes in your supply chain. Our experienced logistics and production experts support you from the initial detailed value stream analysis right through to successful, seamless implementation directly on the shop floor. In doing so, we ensure without compromise that the optimisation measures implemented pay for themselves in the shortest possible time through drastically reduced lead times and minimised stock levels. Take advantage of our cross-sector expertise to gain a measurable competitive advantage and contact us today for a no-obligation initial consultation.

Contact us

We are there for you.
Your contact person

Irene Kocher

T +49 711 3917030

info@ebp-consulting.com

Questions and answers on optimising your production

How quickly does a consultancy project to optimise production planning pay for itself?

The return on investment (ROI) for production optimisation is extremely attractive and, based on experience, is often achieved within just 6 to 12 months. This is primarily due to the immediate reduction in stock levels, shorter lead times and the complete avoidance of costly production downtime. Even though resources are initially tied up in the professional analysis, the long-term savings in manufacturing costs will exceed the project investment in no time at all. Furthermore, more efficient capacity utilisation will significantly and permanently reduce the need for costly overtime shifts.

What internal resources do we need to allocate for a successful restructuring of our production?

For the project to succeed, it is essential that you assign a dedicated core team from the production, logistics and IT departments. This team does not need to be tied up full-time, but should remain available on an ongoing basis for regular value stream workshops and targeted coordination. ebp-consulting addresses concerns regarding day-to-day operations through agile project management that involves your staff highly efficiently without overburdening them. This close integration ensures that the newly acquired expertise remains firmly embedded within your organisation in the long term.

How long does it take to introduce efficient production planning and control?

The project duration varies depending on complexity, company size and the existing level of digitalisation, but typically ranges between 3 and 9 months. A strategic quick check delivers tangible results after just a few weeks, whilst the implementation of comprehensive IT systems naturally requires more lead time. To allay concerns about lengthy disruptions, ebp-consulting employs intelligent, phased roll-outs. This allows initial areas to benefit significantly whilst others are optimised gradually, thereby eliminating the risk to live operations.

Can Lean Production also be applied in cases of high product variety and small batch sizes?

Absolutely. It is precisely with complex product portfolios and ‘high-mix, low-volume’ manufacturing that Lean principles demonstrate their undisputed potential for managing complexity. Instead of relying on rigid takt lines, we implement highly flexible matrix or cell-based production systems that drastically reduce set-up times through intelligent SMED methods. Common concerns that Lean only works in high-volume production have long been disproved in practice by modern, hybrid pull systems. Through modular workstation design, we ensure maximum, waste-free value creation even for batch size 1.

How does ebp-consulting ensure that the new planning is accepted by our staff?

Staff acceptance is the key success factor, which is why professional change management is an integral part of every logistics project we undertake. From day one, we actively involve plant operators and foremen in Kaizen workshops to make direct use of their indispensable practical knowledge. We allay any fears regarding optimisation measures through completely transparent communication and a clear focus on making work noticeably easier. Through this targeted coaching, we empower your team to manage the new processes with pride and confidence.