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Case Study LEAN Production

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Introduction of lean production at an Austrian ski manufacturer

Background:

The renowned ski manufacturer based in Austria was faced with the challenge of optimising its production processes to respond to increasing demand and growing competitive pressure. The company decided to implement LEAN Production to minimise waste, enhance efficiency and further improve the quality of its skis.

Application of LEAN Production

5S Method (Sort, Systematise, Shine, Standardise, Self-discipline):

  1. Implementing a comprehensive organisational reform of production areas to promote order and efficiency.
  2. Establishing clear workstation standards and regular monitoring of compliance.

1. Kanban System:

  1. Implementation of a visual control system for material flow to better synchronise demand and production.
  2. Reduction of overproduction and stock levels through demand-driven production.

2. Kaizen (Continuous Improvement):

  1. Introduction of a culture of continuous improvement, actively encouraging employees to contribute to the process with improvement suggestions.
  2. Regular Kaizen workshops to identify and eliminate bottlenecks and waste.

3. Value Stream Mapping:

  1. Detailed analysis of the entire production process to optimise the flow of materials and information.
  2. Identification of bottlenecks and implementation of measures to improve the overall process.

Results: The implementation of LEAN Production yielded impressive results for Alpsport GmbH:

1. Increased Efficiency: production became more efficient and flexible, enabling a faster response to market demand.

2. Reduction of Waste: by applying LEAN Principles, waste in the form of overproduction, unnecessary stock and inefficient processes was minimised.

3. Increased Quality: the focus on continuous improvement and standardised work processes led to higher product quality.

4. Improved Employee Satisfaction: Dinvolving employees in the improvement process contributed to a positive corporate culture and increased employee satisfaction.

5. Cost Savings: by reducing waste and improving production efficiency, Alpsport GmbH was able to cut costs and strengthen its competitiveness.

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Claudia Flowerdew Claudia Flowerdew
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Bettina Dirks Bettina Dirks
Coordination Consulting & Training
T: D +49(0)89 42 01 74 71
T: A +43(0)1 348 86 86 10
T: CH +41(0)44 500 23 28
E: office@ipic-ag.com

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