Gerhard (W.) Kessler-Director Operations

Consulting, seminars, workshops, and various projects for the Lean-Institute

Kaizen-workshops (print company, chemical industry, metal company)

5-S workshops and implementation

JIT-workshops

Lean assessments and support (fitting industry – metal company)

Value stream analysis (metal industry)

Logistic and material flow analysis and workshop (food industry)

TPM analysis and TPM workshop (chemical industry)

Consulting for small cap companies (organization and processes)

Advisory service for start-up companies

Hired by an English recruiting company to improve the productivity and triple the output of the key supplier to an English client. The entire organization was changed, process improvements and installation of workspace and a reorganization of the logistic system were implemented alongside 5-S, CIP, KPI and Kanban systems. Continuous coaching of the general manager. The output increased by 200% within eight months.

Introduction of lean techniques in an SME medical equipment company. Reorganization of the warehouse to set up an assembly line and create a one-piece-flow line for individual wheelchairs. Implementation of CIP and 5-S.

Process analysis and implementation of lean techniques in a laser cutting company. Creation of a CE-9001-2015 environment and certification within nine months.

Coaching and reorganization of a materials management department to change from day-to-day handling to a more strategic role in a medical device company. Implementation of CIP and parallel analysis of parameters and installed processes.

Re-setup of a medical device company in Italy to achieve DIN ISO 9001 / EN 13485 certification (certified October 2019).

Interim management assignment in a pharmaceutical company to run the logistic department: reduced space by 30%, introduced 5-S and CIP, set up a visual Kanban system.

Process analysis at a pharmaceutical company of intralogistics (incoming, warehouse, shipping, external warehouses). Restructured department workload and set up a lean department.

SME project for material flow and layout analysis and new building setup at a medical apparatus manufacturer.

SME project for process flow improvement and installation of one-piece flow, change of planning mode, installation of KPI, and implementation of CIP in a hydraulic hoses company.

SME project in Beijing, China at a medical device manufacturer (process flow analysis and improvement – 5-S, CIP, installation of KPIs, change of planning mode).

Externalization of sterilization and process analysis of packaging department at a medical device manufacturer.