The V-model for production optimisation

Understand fist - improve afterwards

Ready for Industry 4.0 due to optimised production

Lean production processes are the preconditions for automation and digitalisation. With the V-Model quick improvements in costs, output and lead times can be achieved, and in the long run, the potentials of Industry 4.0 can be elevated.

The V-model for production optimisation


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Download the V-modell

You can download the V-Modell as a PDF document here (no registration required): V-model in PDF (coming soon).   

6 steps to an optimised production  

The V-Model contains an "understanding" axis, an "improving" axis and six steps.  

On the understanding axis, we analyse customer and order structures, identify the production models and production processes (customer process classes) and analyse the existing workplaces and workflows.  

On the improvement axis, the findings are implemented with product representatives in a pilot sector, e.g. through workplace design/lean manufacturing or through the introduction of Industry 4.0 applications (e.g. assistance systems, RFID, visualisation) that produce quick benefits with regard to productivity and quality.  

The pilot sector is the germ cell for improvements. Starting from here the measurements are rolled out according to a step-by-step-plan with guidelines to further working systems and business units.  

Only a measurable outcome is a good outcome  

In the outcome, we finally evaluate the aggregated single measures with the aid of existing and new KPIs - on the one hand with regard to the customer (e.g. delivery time, delivery quality index, delivery service level, adherence to delivery dates etc.), and on the other hand, with regard to the company (e.g. lead time, increase in productivity, stock level, production flexibility, etc.).  

Steps 1-6 at a glance:

  • Determination of order structure and production models     
  • Actual analysis of existing processes  
  • Actual analysis in the pilot sector   
  • Optimisation in the pilot sector   
  • From pilot to the entire production   
  • Key figures for success monitoring and key figures for the cockpit  

Our approach is orientated towards the most frequent goals of our customers in optimisation projects. Mostly, the topic is cost optimisation through output increase in consequence of lead time reduction and/or productivity growth.  

The V-Model is therefore a proven procedure. The employees are involved in the optimisation process and the objectives are adjusted individually in a realistic and sustainable way.  

Quick effects, permanent value added  

Besides the measurable, quick cost optimisation, with our concept, we create a basis for sustainable improvement approaches (CIP culture) in the company.  

By means of precise project goals we do not produce isolated solutions, but we keep the big picture in mind. The interfaces to all relevant departments are considered all the time.   

For example, through greater price transparency and process accuracy the IT systems (ERP, PPS, MES) can be adjusted much more effectively to the production. A higher level of digitalisation/atomisation and the introduction of new IT tools can take place in a targeted way and according to precisely defined parameters. QM/QA measurements can be implemented at those points, where they really produce added value for the customer. The handling of purchasers can be rethought. Layout and logistics structures can be questioned and improved.  

At the end of our optimisation project usually, there is usually a list of potentials that contains several hundreds of positions. In a target concept suggestions for realisation are collected.  

Ready for Industry 4.0  

Last but not least, is the clarity of the process that is achieved by the V-Model, a precondition for future topics such as Industry 4.0, that is a continuously digital cross-linking of all business units (vertical integration). Without clearly defined processes at production level, every Industry 4.0 project will turn in a data and investment grave.