REFA method

Discover hidden efficiency reserves in your logistics using the REFA method and create a robust data foundation for your process optimisation through precise time measurements. As specialist consultants, we support you in sustainably reducing lead times and managing them in a scientifically sound and economically optimal manner.

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Improving efficiency through precise process data in logistics

The REFA method is the gold standard for time recording and process optimisation, designed to unlock hidden potential in your logistics operations through watertight data analysis. Is your aim to radically reduce your lead times? With the expertise of ebp-consulting, you can implement REFA-based time recording as a strategic tool for sustainable profitability. We transform your operational processes into measurable, high-performance processes. Start optimising your supply chain with us now!
   

The REFA method as a strategic lever for logistical excellence

In modern logistics consultancy, the REFA method serves as a fundamental tool for the objective evaluation and design of work systems and processes. The systematic application of this methodological framework enables waste to be identified and capacities to be precisely managed, which directly contributes to competitiveness. ebp-consulting uses this approach to create transparency in complex material flows for C-level decision-makers and to underpin investment decisions with hard facts. In the following sections, you will learn how its operational application stabilises long-term business success.
   

The REFA method explained simply

The REFA method is a systematic procedure for data collection, work design and operational organisation, based primarily on time recording and process analysis. At its core is the REFA time study, in which work processes are broken down into individual elements and timed in order to establish target times for tasks carried out by people and machines. The aim is to create an objective database for remuneration, costing and capacity planning in manufacturing and logistics companies. It combines findings from ergonomics with economic requirements in order to holistically increase the efficiency of work systems.

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The ebp-consulting approach: Methodology meets implementation­strength

At ebp-consulting, we do not regard the REFA method as an isolated measurement tool, but as an integral part of a holistic process optimisation approach. We combine traditional REFA time recording with state-of-the-art simulation tools and our in-depth engineering expertise to not only document current conditions but also proactively develop target concepts. Our focus is on physical feasibility and reducing complexity within your global supply chains. We support you from the initial data collection right through to the final on-site commissioning of the optimised systems. Through this pragmatic approach, we ensure that theoretical savings potential is translated into real, measurable results on your balance sheet.

   

The core components of the REFA method

The REFA time­study for capacity­planning

Carrying out a REFA time­study enables the precise determination of standard­time­values for manual tasks such as order picking or packing. In logistics­practice, this serves as an indispensable­basis. By breaking the process down into stages, time-consuming elements are identified which often remain hidden in opaque processes. ebp-consulting uses this data to create highly precise capacity models for clients, which prevent overloading and eliminate underutilisation.

Objective data basis for freight cost management

Precise time­recording in accordance with REFA also provides critical data for transport­management, particularly during loading and unloading­operations at the loading bay. By accurately documenting time­allocations, dwell­times can be minimised and the throughput­rate at the gates significantly increased. This transparency is crucial for negotiations with transport service providers and for avoiding demurrage charges. We use this data to harmonise interface processes between the warehouse and transport. This leads to the seamless integration of inbound and outbound flows and strengthens your position in carrier management.

Design of ergonomic work systems

The REFA method goes beyond mere time measurement and assesses the physical strain as well as the ergonomic design of workstations. In an SCM context, this means optimising reach distances and working heights to reduce the physical strain on staff. Ergonomically optimised processes have been proven to reduce error rates and improve the long-term performance of the workforce. ebp-consulting integrates these ergonomic aspects directly into factory and warehouse planning. In this way, we create working environments that are both highly efficient and conducive to good health, which is a critical competitive advantage in times of skills shortages.

   

Areas of application of the REFA method in practice

In operational logistics, the REFA method is primarily used where a high degree of repetitiveness and manual effort coincide, such as in large distribution centres or assembly lines. A classic example is the optimisation of order picking, where REFA time recording is used to determine the most efficient picking strategy on a data-driven basis. REFA data also serves as an essential benchmark for before-and-after comparisons (ROI analysis) when introducing new automation solutions, such as AGVs or robotics. We also use the method to standardise processes across different sites in order to ensure a consistent level of service quality throughout the network. In this way, the REFA method forms the foundation for continuous improvement in line with the PDCA cycle.

   

Questions and answers about the REFA method

How does REFA timing differ from a conventional stopwatch measurement?

REFA time recording follows a strict set of methodological rules, which includes an assessment of performance levels in order to objectively neutralise human variation. In contrast to simply timing tasks, process stages are defined and statistical checks are carried out to obtain representative planned times. In consulting practice, this ensures that the results are accepted by both management and employee representatives.

When is the ideal time­ to use the REFA method in a project?

Its use is recommended whenever processes have been stabilised but the exact capacity figures are not available for planning purposes, or when a reorganisation of workstations is due to take place. Particularly before investing in automation, a time study using REFA is essential in order to calculate cost-effectiveness based on actual figures. We often use REFA during the analysis phase to pinpoint the ‘centre of gravity’ of waste.

Is a specific certification required to implement the REFA methodology?

Yes, thorough training provided by the REFA Association is essential to ensure the quality and legal validity of the data (e.g. for remuneration systems). Our consultants possess this expertise and combine it with many years of project experience in the industry. This ensures that the data collected is not only accurate but can also be interpreted strategically.

Can the REFA method also be used in digitised warehouses with WMS support?

Absolutely, because even though a WMS provides data, information on manual ancillary and distribution times – which REFA records precisely – is often missing. The combination of system data and physical time recording enables seamless transparency across the process chain. We utilise this synergy to uncover digital ‘shadow processes’ and to support system efficiency through organisational measures.

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