Case study 1

PARTNER

Our partner has been a wholesaler of high-quality frozen products in the Central European market since 1989. They currently sell 1,037 products and have a complete range of frozen foods. As a major player, they periodically review and optimise their transportation processes.

DEFINED DEVELOPMENT POINTS

Based on a Status Report from a study conducted in 2019, we identified areas that could be further optimised for operation:

  • The introduction of a well-vetted, barcode-based product tracking system, which has become increasingly critical due to a growing product portfolio.
  • The migration of the stock documentation system from paper to digital, which has already begun but needs to be accelerated.
  • In addition to basic knowledge, continued operations require advanced logistics training for employees due to the increase in the number and volume of deliveries.

ADVISORY AREA

Status Report, Planning, Execution
Our company has developed a detailed implementation plan for the aforementioned development points identified based on the Status Report, including design, procurement, implementation, training, follow-up, and periodic control.

Case study 2

PARTNER

Our partner is a printing company that has been operating in the Central European market since 1990. Their products include traditional printing products, from simple flyers to high-quality hardcover books and special packaging materials used in industrial applications. In addition to their well-trained technicians, their state-of-the-art technical background guarantees world-class quality.

ADVISORY AREA

Status Report, Planning, Consultancy
Our partner needed to move to a new factory to meet ever-growing customer needs. Important considerations when designing a new production plant include: having the right size, arranging the machinery as efficiently as possible, and making the move as quickly as possible.
Our company designed the optimal floor plan based on the Lean approach and demonstrated its advantages to the partner with the help of simulations. Thanks to this, the new plant has become much more efficient, and we were able to improve upon many previous processes via new machines.

Case study 3

PARTNER

Our partner, a company established in 1997 that has seen rapid growth, is a strategic partner and supplier of large multinational machine manufacturing companies. Its primary expertise is the production of specialised parts and tools. With a total floor area of ​​15,500 sqm, the partner utilises many modern innovations, such as welding robots.

DEFINED DEVELOPMENT POINTS

To help our partner maintain and strengthen its position with its clients, we embarked on a comprehensive development project, which was partly funded by a grant. Following the site visit, we identified several optimisable points in operation as part of the Status Report:

  • There was no available information on the machines used in production, and there was no efficiency measurement system in place
  • The accelerated migration of the product documentation system from paper to digital
  • The software used throughout the process was inconsistent, some systems were incompatible with one another; some workflows were recorded and designed in Excel

ADVISORY AREA

Status Report, Planning, Consulting, Execution, and Implementation
The optimisation opportunities we discovered were mainly focused on providing a comprehensive view of the manufacturing process in a complex system. To do this, we designed a sophisticated software solution with a new network infrastructure plan, making sure that different types of machines could be connected to the new system, and we prepared the system for future upgrades. Most importantly, we prepared this entire process within a framework that led to a successful grant application.

Case study 4

PARTNER

Our partner is a major player in the international pharma sector and currently supplies active ingredients and products to 108 countries worldwide. The operation supports many member companies and subsidiaries with separate production, sales, and R&D departments. Because of the intense competition in this sector, efficiency is integral to the company’s success, so it reviews its operations regularly.

DEFINED DEVELOPMENT POINTS

Following the site visit, our Status Report identified two areas of improvement that would ensure significant profit growth:

  • In many cases, the production efficiency required by the company itself was not attainable, but it could be significantly improved by re-designing and optimising the systems
  • The standardisation of data collection for production lines, equipment, and machines

ADVISORY AREA

Status Report, Planning, Schedule Preparation
LCG developed a detailed system plan and timetable for the development points identified in the Status Report. Based on this, plans have been submitted to establish an OPC Data Collection Network, which is currently being approved.

Case study 5

PARTNER

Our customer is an internationally renowned healthcare provider with a presence in 64 countries. They have three subsidiaries in Hungary alone that employ 3,483 people in 2020. To meet the increased market demands, the company is working on establishing a new factory in Hungary, which will mean a larger volume and new product lines for domestic production.

DEFINED DEVELOPMENT POINTS

In addition to a site visit focusing on current processes, the planned production line also received special consideration in the Status Report. The following are the main points elaborated in the workshop held after the Status Report:

  • We recommended upgrading the current production line, including the replacement of many machines.
  • The replacement of QC class assets has become necessary due to extra tasks.
  • Increased space in revised plans for the new R&D unit and microbiology laboratory — our analyses concluded that they received significantly less space than in the original design of the units.
  • Throughout implementation, optimisation of connection points and utility demands has also become crucial.

ADVISORY AREA

Status Report, Planning, Construction Preparation
LCG developed a detailed schedule for replacing the machines in the existing plant with a focus on efficiency and reliability. In the new plant, precise connection points and locations have been specified, tailored to the optimal productivity, and we have designed and visualised the complete equipment, furniture, and engineering of the QC, R&D, and microbiology labs according to the customer’s requirements and the most efficient layout.

Case study 6

PARTNER

Our partner is a food industry company that has been operating in Central Europe for 27 years. They process and package fresh FMCGs using grading, washing, drying, and packaging equipment. The company’s focus is to set itself apart on the market with healthy and fresh products at all times, all while continuously improving its products and food safety standards.

DEFINED DEVELOPMENT POINTS

We partnered with this client with the express goal of increasing their efficiency. Following the site visit, the Status Report revealed the potential for improvement in the following areas:

  • They could not extract data from their current production line, so they had no information on efficiency, water usage, or energy consumption. Instituting defined measuring points has become essential, especially due to the expanding nature of their product portfolio.
  • Heat distribution, which is necessary to maintain high quality, was not uniform during production.
  • The water mixing process could not be regulated at a high level.

ADVISORY AREA

Status Report, Planning, Construction
LCG developed a detailed implementation plan for the development points identified in the Status Report. As part of this, a ThingWorx platform for data collection was built into metering devices, which were then integrated into the plant’s systems. Moreover, we planned a PLC system for control of the water mixing process, which we also incorporated into ThingWorx system, and we instituted temperature control supported by MPC methodology.

Case study 7

PARTNER

Our partner is a trading partner of multinational companies that offers complete solutions to their food industry customers, from food processing systems to filling lines to beverage/carton packaging.

DEFINED DEVELOPMENT POINTS

One of the building blocks of efficiency — the relationship and communication between management and employees — needed improvement. Recognising their weakness in this area, our partner asked us to organise the gathering of ideas from employees, who were constantly coming up with improvements.

Solution (methodology):

  • On-site tour
  • Understanding processes
  • Develop a reward system
  • Web interface design and development
  • Automatic design and installation
  • Designing and implementing a reward and compliment card system

ADVISORY AREA

Status Report, Planning, Consulting, Construction.
After reviewing the processes, we have developed an optimised web-based system through which employees can submit their suggestions and feedback to senior management; senior management could then reward employees with points, which employees could redeem as gifts. In addition, suggestions were saved and organised in a database to facilitate later usage.

Case study 8

PARTNER

Our partner has world-class industry expertise and experience in industrial and mobile hydraulics, linear actuation and assembly technology, electric drives, and controls.

DEFINED DEVELOPMENT POINTS

The company is dynamically evolving year by year, and its company processes could not keep up with this growth, so the much-needed expansion of a production facility provided the opportunity to rethink its production layout and processes.

Solution (methodology):

  • Create a current state map of the value stream
  • Define development potential
  • Create a future status map
  • Create a Lean/Kaizen vision
  • Define development sub-projects
  • Draft a comprehensive development plan (12-24 months)
  • Predict goals and results
  • Address resource planning needs

ADVISORY AREA

Status Report, Planning, Consulting, Construction.
Based on the Lean Management approach, we explored the current state of company operations with our senior management. During the development of the current state value flow map, LCG identified several potential areas of development that could guarantee the reduction of ongoing losses.
While drawing the future status map, we created a guideline for Lean development and defined related sub-projects. We prepared a comprehensive development plan, in which we analysed and planned the achievable goals and the necessary resources. The result of this analysis is well suited to the continuous development of the company and the preparation of the next steps in digitalised production. Indeed, the revenue and profit growth the growth achieved through these improvements was made quantifiable

Case study 9

PARTNER

Our partner has powerful brands, innovative technologies, and extensive experience in the printing, packaging, office supplies, bookbinding, and paper processing industries.

DEFINED DEVELOPMENT POINTS

The machine control software developed for the company did not work properly, and because of this constant malfunctioning, there were delays that impacted various lines of business. Thus, important resources had to be spent on troubleshooting, with significant loss of revenue, profit, and market share. The projects involved many machine lines in several countries across multiple continents. Various versions of programmes running on production lines further increased operational difficulties. We had to unify these challenges and provide the optimal transnational solution.

ADVISORY AREA

Status Report, Planning, Consulting, Construction.
We built a complex understanding of current processes following the review of user manuals, Excel flowcharts, the complex wiring diagrams, and reference programmes. With this understanding, we unified the structure of the programme, defined new programme points, and reprogrammed key functions. The system now functions seamlessly across continents, freeing up time for our partner to tackle more significant business challenges.