Initial situation:
- Shopfloor Management (SFM) was partially implemented, with limited buy-in at all management levels.
- Lack of consistent coaching, with trained multipliers but no master coach on site.
- Gaps in KPI understanding, employee empowerment, and use of Lean tools.
- Inefficient cross-functional collaboration and process ownership.
Our approach:
- Established clear SFM governance and anchored it across management levels.
- Provided intensive coaching, mentoring, and shadowing to develop internal capabilities.
- Conducted workshops and hands-on learning sessions to build practical skills.
- Co-created solutions with local teams to ensure ownership and sustainability.
- Focused on Lean leadership development and cross-functional cooperation.
Results:
- Up to 650,000 € annual savings through reduced rework, scrap, waste, and headcount inefficiency.
- Improved KPI transparency and systematic countermeasure implementation.
- Stronger process ownership and employee empowerment across 13 segments.
- Sustainable SFM structure, closing the lighthouse phase successfully.
- Significantly enhanced Lean leadership culture.
Conclusion
A comprehensive SFM reset delivered measurable cost savings and long-term cultural change.
