Sharing knowledge successfully: Insights at Noventa

Participants from over 50 Tyrolean and Bavarian companies gathered for the 22nd meeting of the Lean Six Sigma Experience Group. The focus was on a visit to the Swiss production plant Noventa AG in Diepoldsau. Lean management has long been part of everyday life here, and the participants were able to experience this first-hand: practical applications in a wide range of areas.

Noventa AG is a Swiss manufacturing company that develops and produces plastic parts for various industries, ranging from the automotive sector to medical technology. The company is known not only for its precise manufacturing processes, but also for its consistent application of lean management principles throughout its entire site.

The event kicked off with a company presentation, followed by a tour of the premises and a joint lunch. In the afternoon, a workshop provided an opportunity to exchange experiences and gain deeper insights into the challenges of implementing lean management approaches.

WHERE CHALLENGES LEAD TO SOLUTIONS

As a contract manufacturer for various industries with its own products, the company had to contend with the challenges of a cost-intensive location a few years ago. It used this situation as an opportunity to fundamentally change its manufacturing philosophy and introduce lean management concepts in order to maintain and expand the location.

The focus is on an efficient and transparent production system based on several proven methods: Physical Kanban cards are central elements for controlling material flows and production orders. These are clearly displayed on boards, showing which goods are in production or in stock. The orders are then scheduled in the Heijunka board, a planning tool for even production distribution.

Furthermore, quality assurance does not begin at the end of the production line, as each part is checked after every step to ensure that it is flawless. This ensures that no defective parts are passed on. Poka-Yoke aids, i.e., simple technical devices, prevent typical errors from occurring during the work process.

Material supply follows the pull principle: only as much material is provided as is actually needed. This keeps inventories low, so that only as much capital as necessary is tied up. Electronic displays inform employees about the order status in real time. Visualization is very important: colored markings, digital display boards, and shop floor boards (overview boards in the factory floor) provide current key figures for daily briefings within the team.

LEAN LIVING, SHARING KNOWLEDGE – PERFECTION IS AN ONGOING PROCESS

Based on its own successful lean transformation, Noventa AG founded a second business division: Noventa Consulting AG, a lean consulting firm that passes on practical experience and knowledge.

During discussions with the experience group, a number of other key points emerged, demonstrating that lean management is an ongoing process. Mutual exchange and knowledge sharing are crucial to achieving continuous improvement.

Links:

• Noventa AG | Website
• ERP Systems & Business Process Management | pt
• ERP-Competence Center | Research Project
• Lean Lab | Science Labs