What is crucial for the production ramp-up after the crisis?
Increasing productivity: The new reality requires new structures. Photo: Shutterstock
Performance Transformation 4.0 - A structured six-step model for realigning your production
In times of economic uncertainty, geopolitical tensions and disruptive market changes, manufacturing companies face a twofold challenge: on the one hand, they must remain capable of acting in the short term and, on the other, they must strengthen their operational resilience in the long term. Traditional restructuring measures often fall short here - what is needed are holistic, structured transformation approaches that combine efficiency, agility and future viability.
With Performance Transformation 4.0, Lean Group GmbH offers a tried-and-tested framework that enables companies to analyze, realign and sustainably optimize their production along six clearly defined steps. The focus is on operational excellence, lean processes and measurable value creation - always taking individual framework conditions into account.
1. assess - evaluate initial situation & identify fields of action
Every transformation begins with a precise understanding of the current situation. Only those who have a clear understanding of their current starting position can make well-founded decisions about necessary changes. The first phase therefore involves a structured analysis of your operational performance.
We work with you to assess the economic viability of ongoing business operations and identify cost drivers at personnel and process level. We focus in particular on business-critical activities that either need to be stabilized or restructured in a targeted manner. At the same time, we organize your teams in line with the requirements of a changed reality - in a targeted, transparent and fact-based manner.
2nd monitor - guarantee safety level & ensure operational readiness
Before a stable restart can take place, health, technical and organizational safety standards must be ensured across the board. In the second phase, we are therefore concentrating on the systematic review of workplace safety and operational readiness.
In addition to implementing company-wide health monitoring structures, we evaluate the availability and effectiveness of personal protective equipment (PPE), validate workplace standards under new conditions and create robust control mechanisms for adapted processes. The aim is to create an environment that combines safety with operational efficiency - a basic prerequisite for any sustainable transformation.
3. diagnosis - simulate risks & recognize transformation potential
As soon as safety and operational capability have been established, it is important to identify potential risks at an early stage and prepare suitable countermeasures. In the third phase, we use targeted simulation scenarios to test the resilience of your processes under realistic conditions.
We analyse possible bottlenecks in the infrastructure and supply chain, assess financial and health risk potential and derive areas of action for the subsequent reorganization. An accompanying change management programme ensures that your organization is not only technically but also culturally prepared for the upcoming changes.
4. redesign - establishing future-proof structures and processes
Now the actual transformation begins. Based on the previous diagnostics, we design a future-proof production model that harmonizes efficiency, flexibility and robustness. The aim is to establish complexity-reduced, high-performance processes - and to anchor them structurally in the organization.
To this end, we reorganize existing processes, define new responsibilities and implement realistic key performance indicators (KPIs) that enable objective management. Lean are not applied in isolation, but are understood as an integral part of a new operational culture - practical, measurable and sustainably effective.
5. stabilize - sustainable anchoring through Lean excellence
Change alone is not enough - it must be integrated into everyday life and made permanent. In the fifth phase, we therefore concentrate on stabilizing and standardizing the new structures. The aim is not only to achieve operational excellence, but to secure it in the long term.
By using proven Lean such as flow, Takt and pull principles, we increase process reliability, reduce error rates and optimize the use of resources. At the same time, we establish rapid response teams that react flexibly to deviations and ensure continuous improvement. The result: a resilient, adaptive organization.
6. execute - managing, anchoring and scaling transformation
The final phase does not mark the end, but the transition to a new operational reality. The task now is to manage the newly created structures in the long term, measure success and develop them further. Transformation becomes a continuous management task.
We support you in establishing central control mechanisms, systematically measuring performance and actively monitoring operational implementation. We focus on the further development of personnel and technological skills as well as the final review through internal audits. In this way, we ensure that your transformation is not only implemented, but anchored sustainably - economically, culturally and strategically.
Conclusion: transformation needs structure - and a strong partner
With Performance Transformation 4.0, we at Lean Group GmbH offer a practice-oriented model that translates complex challenges into concrete solutions. Our strength lies in the combination of in-depth analysis, methodological excellence and operational implementation expertise.
Whether crisis management, cost reduction or strategic realignment - we provide you with holistic, structured and partnership-based support. Take advantage of our expertise to make your production resilient, efficient and future-proof.