Production
Operations.
Our experienced and hands-on consultants are ready to redesign, develop, implement and continuously improve all process aspects and interfaces with your company in a joint team to find sustainable and competitive solutions.
No matter the sector or environment: from an API manufacturing facility to filling and finishing CMOs, or even in complex medical device manufacturing.Visible.
Productive.
Agile.
Do you want to optimize you Production Operations?
Our Approach.
The path to an efficient and transparent Production Operations process landscape.
To ensure adequate output in a manufacturing environment with 24/7 operating hours, factors such as visual performance management, real-time monitoring and tracking, data-driven decision making, and lean and operational excellence are key to maintaining competitiveness.
Lansagme and uncoordinated plant changeovers, poorly integrated cleaning validations, or shift changes that are not fine-tuned and unorganized can already lead to major disruptions and operational difficulties. And this is only a small part of the problems a production site can face.
Our Entourage experts don't just focus on the typical manufacturing-related issues and bottlenecks. They care about the big picture including every major interface with examples such as production wait times due to IPC measurement QC issues, recurring and inefficient production slot changes due to non-transparent, poor forecast quality, or simply unreleased or untested source materials due to unclear and fragmented communication, planning, or even time-consuming paperwork.
Finding and quickly onboarding shift managers, production staff, and/or operators within a short period of time can also be challenging and is supported by one of our implementation managers to ensure maximum remaining capacity for day-to-day operations.
The following is a proposed consulting team that includes all the disciplines necessary to co-create a more transparent, efficient, up-to-date, and proactive manufacturing operations landscape at your company or site.
Our offer in Production Operations.
Eight ways Entourage supports customers in Production Operations.
- Process flow visualization and analysis incl. industry best practice benchmark
- Visual management incl. key figures, workload tracking, capacity planning, resource scheduling and advance production planning incl. plant changeover
- Technical as well as product transfer, outsourcing and third party management
- Lean, Six Sigma and OpEx levers in the manufacturing and engineering environment including competency building, change management and building lean academies or change agent programs.
- Intelligent, transparent factory and central project management organization with digital solutions
- IT infrastructure strategy, equipment qualification, computerized system validation and data integrity.
- Monitoring of CAPEX, or investment projects
- Design, construction and installation of cleanrooms and heating, ventilation and air conditioning (HVAC) systems, including qualification.
Our services in Production Operations.
What you can expect from Entourage's production experts.
Transparency.
- Status quo diagnosis of the process landscape and tools incl. best practice benchmarks
- Identification of appropriate improvement levers, e.g. digital prototype for visual performance management
- Establishment of a central PMO to control, track and plan projects
- Interface collaboration to avoid isolated approaches and increase cross-functional, multi-site transparency
- Concept of a "control tower" as the only true source of numbers, data, facts and important information
Reduction.
- Establish a system to measure overall equipment efficiency (OEE) and manage downtime.
- Introduction of an optimized shift model with better coordination and fast, well-integrated handover
- Redesign of deviation and especially OOS management towards an efficient cross-functional process flow
- Reduction of time-consuming paperwork through standardization and partial automation, e.g. document or batch record review
- Reduction and acceleration of device replacement
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Reduction of inconsistencies in interface collaboration
(R&D, Production, QC, Supply Chain and Sales)
Efficiency.
- Identify the level of innovation of Lean and OpEx in the company.
- Development of improvement levers ready for piloting and rollout
- Training and coaching employees to become Lean Change Agents.
- Establishment of a Lean Academy to disseminate know-how within the teams
- Conducting workshops with senior experts for further competence building and change management
- Establish a mentality of continuous improvement through quick wins, positive reinforcement, and training and reinforcement of new skills
Production Operations Expertise.
Get to know our experts.
Ulrike Heimann
Lean, Six Sigma, and OpEx specialist in manufacturing and technical environments.
Merlin Idris
Specialist for advanced analytics, digitalization and smart factories
Dirk Düsterhöft
Computer system validation, data integrity and IT infrastructure expert
Dr Thomas Koblizek
MedTec and IVD expert for production planning, management and transfer
Our Case Studies.
Discover our Case Studies in Production Operations.
Our blog.
The latest articles on Production Operations.
