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Optimization of Production Management and
Material Flow – Trodat GmbH
Client
Trodat GmbH
Task definition
Optimization of production controlling and material
flow
Duration
07/2004 to 12/2004
Within the framework of a comprehensive realignment of production in Wels the
production strategy improved fundamentally. Due to the high variety of products, the semi-finished products were produced directly in the store and assembled according to the order. The storage conditions were changed in such a
way that the available storage places were no longer sufficient and the logistics
of material flow in the production was difficult to deal with and to control.
During the project the production controlling was transformed into market
controlling, lot sizes were reduced, material flow was optimized so that without
the extension of storage it became possible to reach growth in sales by 30% in
further outcomes even with the existing structures.
Task definition
At the beginning of the project the following goals were defined by
Trodat GmbH:
 Comprehensive analysis of logistics (structures, processes,
controlling principles, flow of materials)
 Optimization of production controlling in particular the logistics of
material flow (which material should be placed where and in which
amount etc.)
 Designing a basic model for decision-making in order to broaden
storage area
 Transforming pilot branches after the optimization of production
controlling
 Roll-Out planning for a comprehensive change process
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Services of ICG
 Offering rapid diagnosis about the situation (strategy, structures,
processes, corporate culture, leadership and communication,
controlling principles, flow of materials)
 Designing simulation models in order to examine the possible effects of different controlling principles on the production (conditions
of storage, set-up time, lot sizes etc.)
 As a simulation implementing a practical management game for the
management team in order to raise their awareness about the effects of various controlling principles
 In-depth optimization and design of the production controlling together with the core management team
 Project management and controlling the entire project together with
the management team
By the real-time implementation of the new processes developed, the
new principles and behavioral model could be continuously practiced.
After less than a half-year period the major project goals have been
demonstrably achieved and even exceeded.
From the very beginning of the change processes ICG supported the
project. In particular great emphasis was put on the involvement of the
people concerned and the relevant knowhow – responsible for accepting results and securing change processes.
Results
Within a half-year period the following results were achieved:
 According to the pull-principle, implementing a demand-driven and
self-directed production line
 Optimization of material flow from 64 meters to 22 meters of logistical way
 Massive reduction of lead-time (reduction > 50 %)
 Reducing supplies of semi-finished products by 65 % and raw
materials by 50 %
 Reducing the value (in EUR) of the semi-finished products and the
raw materials by 50 %
 Increasing productivity of personnel
 No further investments was necessary in the extension of the storage area after the implementation of change processes and with the
new production model a further growth in sales from 30 % was possible in the following years
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