Gottfried Forster-Process Analyst/REFA Consultant
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Experience
Production
Automotive Industry
- Process analyses
- Cycle times
- Standard times
- Productivity improvement measures
- Multi-machine operation
Production planning
Drive Shafts
- Training in production planning with the IPASWIN system
- Process analyses
- Process optimization
- Planned time set-up
- Standard time calculation
- Potential analysis
- Production line balancing
Production planning
Warehouse Technology
- Training in production planning with the IPASWIN system
- Planned time values
- Planned time formula
- Regression calculation
Production
Medical Technology
- Process analyses
- Standard times
- Productivity improvement measures
- Process optimization
Machining
Automotive Industry
- Process analyses
- Multi-machine operation
- CNC machining
- Weak point analysis
- Creation of an OPL action list
- Measures and savings potentials
Logistics
Food Industry
- REFA multi-moment study
- potential analysis
- PDCA action list for productivity improvement and staffing capacity
Production Planning
Food Industry
- REFA process analyses
- productivity improvement
- process optimization
Assembly
Defense Industry
- process analyses
- review of standard times
- planning figures
- weakness analysis
- creation of an OPL action list
- savings potentials
Switch Cabinet
Switchgear
- process analyses
- review of standard times
- planning figures
- setting up standard time systems
Machining
Automotive Industry
- optimization of production lines
- process analyses
- cleaning and repair
- shop floor management
- coaching of managers and employees
- production planning and control
- KPI system
- OEE productivity improvement
- workplace optimization
- personnel planning
Production
Print & Media
- REFA process analyses in the area of offset and digital printing
- Cutting
- Folding
- Packing and shipping
- Warehouse organization
- Created standard time values and costing metrics
- Layout and material flow planning
- Implementing and supporting PDCA measures
- Organizational structure
- Job descriptions according to ERA
- Potential analysis
- KVP workshop
- Workstation design and organization
Assembly
Medical Technology
- Process analyses
- Reviewing standard times
- Planned figures
- Weakness analysis
- Creating an OPL action list
- Savings potential
Logistics
Food Industry
- REFA multi-moment study
- Potential analysis
- PDCA action list to improve productivity and personnel capacity
Machining
Space Systems
- REFA time studies
- CNC machining center
- Potential analysis
- PDCA measures
- Target vs. actual comparison of standard times
- Savings potential
Assembly
Defense Industry
- Process analyses
- Reviewing standard times
- Planned figures
- Weakness analysis
- Creating an OPL action list
- Savings potential
Electronics Vulcanizing
Switchgear
- Process analyses
- Checking standard times
- Target figures
- Multi-machine operation
- Bottleneck analysis
- Creating an OPL action list
- Savings potential
Assembly
Automotive Industry
- REFA time studies
- Optimizing one-piece flow workstations
- KVP measures
- Checked and updated standard times
Production
Turned Parts Industry
- REFA setup time analysis
- Setup time optimization
- Measures to increase productivity / optimize machine runtime (OEE)
Production
Print & Media
- REFA process analyses in offset and digital printing
- Cutting
- Folding
- Packaging and shipping
- Warehouse organization
- Created standard time values and calculation metrics
- Layout and material flow planning
- Implemented and supported PDCA measures
- Organizational structure
- Job descriptions according to ERA
- Potential analysis
- KVP workshop
- Workstation design and organization
Production
Filter Technology
- REFA time studies
- Checking and updating standard times
- Potential analysis
- PDCA measures for productivity improvement and cost reduction
- Planned vs actual comparison of planning data
- Production data management
Mechanical Machining
Medical Technology
- REFA time studies
- Check and update standard times
- Compare planned vs actual data
- Production data management
- Goal: Planning reliability
Assembly
Medical Technology
- REFA time studies
- Check and update standard times
- Potential analysis
- PDCA measures to increase productivity and reduce costs
- Planning reliability
Production
Medical Technology
- REFA time studies
- Bending
- Welding
- Wire basket manufacturing
- Potential analyses
- List of PDCA measures for productivity improvement
Baking Line
Food Industry
- REFA multi-moment study
- Potential analysis
- List of PDCA measures for productivity improvement
Bakery Production
Food Industry
- REFA multi-moment study
- Potential analysis
- List of PDCA measures for productivity improvement and personnel capacity
- Equipment maintenance
Machining
Automotive Industry
- Reviewing and updating standard times
Assembly
Automotive Industry
- Reviewing assembly processes and standard times
- Potential analysis
- Continuous improvement projects
Assembly
Electronics
- REFA time studies
- Final assembly
- Further development of plan time structure
- Plan time formulas
- Plan time values
- New product calculation system
Assembly
Pumps
- REFA time studies
- Reviewing and updating standard times
Machining
Automotive Industry
- REFA time studies
- Multi-machine operation
- Machining
- Process optimization
- Productivity improvement
Assembly
Automotive Industry
- REFA time studies
- time data management
- time data review and update
Assembly
Automotive Industry
- REFA time studies
- review and update standard times
- calculation and planning fundamentals
- process optimization
- tool optimization
Assembly
Automotive Industry
- video analyses
- review and update standard times
- video analyses
Assembly
Electronics
- REFA time studies
- final assembly
- set up a standard time structure
- standard time formulas
- standard time values
- build a costing system
- continuous improvement projects
Assembly
Mechanical Engineering
- REFA time studies
- productivity improvement measures
- organizational structures in production
Assembly
Automotive Industry
- Potential analysis
- Process optimization
- Layout and material flow planning
- Assembly line balancing
Series start-up
Automotive Industry
- Project manager for product launch / ramp-up in battery production
- Layout and material flow planning
- Logistics concept
- Assembly line
Vulcanizing
Automotive Industry
- Production data management
- Checking standard times and work contents
- Productivity
- Operating multiple machines
Assembly / Coating
Pump Systems
- Process analyses
- Process optimization
- Preparation of cost calculation bases
- REFA time studies
- Potential analysis
- Layout and material flow planning
- Implementation of measures in the packing area
- Productivity improvement
- Value-added projects
Fan Technology
Automotive Industry
- Process analyses
- Updating calculation bases and productivity
- Weakness analysis
- Process optimization
- Measures to increase productivity and equipment utilization (OEE)
- Implementation of measures
Personnel
Automotive Industry
- Workspace evaluation according to ERA
- Checking job classification
- Expert report
Electronics / Series Ramp-Up
Aerospace Industry
- Interim Launch Manager (6 months)
- Process planning and implementation of new projects through series production
- Organization and coordination of involved departments up to series readiness
- Change management
Lean
Pump Systems
- Layout and material flow planning - new build -
- Concept development of organization, org chart, tasks
- Setting up flow production, process organization, workstation design
- Concept development for module assembly
Assembly
Pump Systems
- Process analysis within the value chain
- Identifying saving potentials to increase efficiency and productivity
Machining
Aluminum Industry
- Coaching in REFA method training
- TWI (Training Within Industry)
- Theory and practice
Packaging
Aluminium-Industrie
- Layout and material flow planning
- Implementation of measures
- TWI Training Within Industry
- Work methods for productivity improvement
Packaging / Shipping
Aluminium-Industrie
- Process analyses in packaging
- Potential analysis - layout and material flow planning
- Implementation of measures
- TWI Training Within Industry
- Optimized packing performance
Electronics
Automobilindustrie
- Concept development for productivity improvement in SMD assembly
- Final inspection
- Transport
- Logistics
- Optimization of equipment utilization
Fan Technology
Automobilindustrie
- Process analyses
- Production line cycle balancing
- Weakness analysis
- Process optimization
- Measures for productivity improvement and equipment utilization (OEE)
- Implementation of measures
Mechanical processing
Automobilindustrie
- Process analyses
- Production line cycle balancing
- Weakness analysis
- Process optimization
- Measures for productivity improvement
- Implementation
SMD placement
Automotive industry
- Process analyses
- Component picking
- SMD and conventional placement
- Optimization of travel routes for SMD placement
- Setup time optimization
- Final inspection
- Visual inspection
- Operating multiple machines
- Weakness analysis
- Capacity planning for personnel
Turbo housing
Automotive industry
- Process analyses
- Production line pacing
- Weakness analysis
- Process optimization
- Measures to improve productivity and equipment utilization (OEE)
- Implementation of measures
- Shopfloor management
Welding line
Wire basket systems
- Process analyses
- Weakness analysis
- Process optimization
- Measures to improve productivity and equipment utilization (OEE)
- Implementation of measures
Logistics
Cosmetics, pharmaceuticals, food, technical products
- Layout and material flow planning
- FIFO storage planning
- Concept development for implementing measures
Base line
Furniture industry
- Process analyses
- Determination of planned time values
- Weakness analysis
- Measures to improve productivity
Shipping
Furniture Industry
- Process analyses
- Determination of new standard time values
- Work method and work system description
- Potential analysis – layout and material flow planning
Anodizing
Surface Finishing
- Process and cost analyses for producing the carrier variants
- Created costing concept
Automatic Packaging Stations
Aluminum Industry
- Process analysis – shift observations
- Error analysis on the automatic packaging stations
- Concept development to increase productivity
Manufacturing
Aluminum Industry
- REFA training
- TWI Training Within Industry – identifying value and waste
- Saving potentials
- Implementation of measures
Packing Station
Aluminum Industry
- Process analyses at the packing station
- Saving potentials – implementation of measures, TWI Training Within Industry
- Identifying value and waste
- Optimized packing performance
Electronics / Logistics
Automotive industry
- Workplace evaluation according to ERA
- Review of job classification
- Expert reports
Transmission production
Automotive industry
- Multimoment analyses to determine time allowance rates
- Process and setup time analyses
- Material flow and layout planning
- Shop floor management
- Staff planning
- Coaching employees
- Multi-machine operation
Logistics
Automotive industry
- Process analyses
- Determination of staffing requirements
- Concept for productivity improvement
Assembly
Automotive industry
- Process analyses
- Determination of standard times
- Measures for process optimization
- Savings potentials
- Productivity improvement (Poland plant)
Assembly
Automotive industry
- Process analyses
- Process optimization of manufacturing cells
- LEA management
- Shop floor management
Assembly
Automotive industry
- Process analyses
- Determination of cycle times for production lines
- Creation of cycle time schedules
Assembly
Automotive industry
- Process analyses on production lines
- Station balancing
- Optimized material logistics
- Workflow organization
- Workplace design
Prototype construction
Automotive industry
- Process analyses
- Tube manufacturing
- Deep drawing
- Setup time optimization
Deep drawing
Automotive industry
- Process analyses
- Assessment of added value
- Savings potentials
- Concept for productivity improvement
- Implementation of measures
- TWI Training Within Industry - Production -
Wheel loader
Vehicle construction
- Process analyses
- Standard time determination
- Preparation of calculation bases
Palletizing and packaging
Cosmetics, pharmaceuticals, food, technical products
- Process analyses
- Value-added assessment
- Savings potential
- Concept for improving productivity
Electroplating, powder coating
Surface finishing
- Process analyses
- Created calculation sheets for sales
- Employee coaching
- Packaging optimization
- Shipping
Manufacturing
Aluminium industry
- Process documentation
- Production planning
- System selection for production visualization – Industry 4.0 –
- Shop floor data collection
- KPIs
- KPI evaluation
- Actions
Mechanical machining
Automotive industry
- Interim project: Lean management for mechanical manufacturing
- Introduction of shop floor management
- Actions
- Scheduling
- Implementation
Assembly
Automotive industry
- Assembly line balancing
- Cycle times
- Potential analysis
- Workplace design
- Actions
- Implementation
Assembly
Automotive industry
- Process analyses
- Savings potentials
- Production line cycle times
- Actions
- Implementation
Injection molding
Automotive industry
- Setup time optimization – injection molding –
- Potential analysis
- Workflow organization
- Planned time modules
Incoming goods
Wood industry
- Process analyses
- Potential analysis
- Actions
- Implementation
- Layout planning
Packing
Surface finishing
- Interim project: packing
- Direct packaging
- Actions
- Implementation
- Coaching of employees
Packing / Shipping
Surface finishing
- Process analyses
- Setup of a planned time system
- Creation of calculation sheets
- Variants
- Preliminary costing
Organization
Sondermaschinenbau
- Process analyses
- Identifying work contents in the invoicing area
- Shipping
- Complaints
- Purchasing
- Receiving
- Accounting
Final Assembly
Automotive Industry
- Process analyses
- Savings potentials
- Actions
- Implementation
Final Assembly
Automotive Industry
- Coaching REFA employees
- Work methods
- Savings potentials
- Productivity
Fan Technology
Automotive Industry
- Production data management
- Process analyses
- Updating standard times and cost calculation data
Assembly
Automotive Industry
- Process analyses
- Savings potentials
- Production line balancing
- Actions
- Implementation
Organization
Automotive industry
- Production planning and control - control center process optimization in production planning and
Assembly
Office furniture
- Process analyses
- Standard time determination
- Savings potentials
- Measures
- Implementation
- Layout and material flow planning
- Workplace design
Visual inspection
Turned parts
- Process analyses
- Savings potentials
- Layout and material flow planning
- Measures
- Implementation
Assembly
Lighting technology
- Process analyses
- Standard time systems
- Calculation basics
- Standard time calculation
Production
Lighting technology
- Process analyses
- Standard time determination
- Cycle times
- Savings potentials
- Measures
- Implementation
- Introduction of standard time system
Final Assembly
Lüfter Technik
- Process analyses
- Standard time determination
- Savings potential
- Measures
- Implementation
Final Assembly
Medizintechnik
- Process analyses
- Workspace design
- Layout and material flow planning
- Coaching of REFA staff
Production
Schaltertechnik
- Process analyses
- Standard time determination
- Cycle times
- Savings potential
- Measures
- Implementation
Mechanical Machining
Sondermaschinenbau
- Interim project: Production management
- Mechanical production
- Savings potential
Assembly
Automobilindustrie
- Process analyses
- Standard time determination
- Savings potential
- Measures
- Implementation
Assembly / Mechanical Processing
Automotive Industry
- Process analysis
- Standard time determination
- Savings potential
- Production line cycle time
- Actions
- Implementation
- SMD assembly
- Power setup
Surface Finishing
Automotive Industry
- Process analysis
- Standard time determination
- Cost comparisons with competitors
Assembly Line
Fluid Technology
- Process analysis
- Standard time determination
- Savings potential
- Actions
- Implementation
Drilling Line
Wood Industry
- Process analysis
- Standard time determination
- Cycle times
- Savings potential
- Actions
- Implementation
- Piece rate / machine usage remuneration
Powder Coating
Surface Finishing
- Process cost determination
- Savings potential
Mechanical processing
Custom machine manufacturing
- Interim project: production management
- Mechanical production
Turned parts
Automotive industry
- Bottleneck analysis
- Optimizing and line balancing of production lines
- Utilization rate
- TPM shifts
- Cost-saving potentials
Assembly
Automotive industry
- Bottleneck analysis
- Measures for process optimization
- Implementation
Assembly
Automotive industry
- Optimization of production lines
- Cycle time adjustment
- Capacity calculation
- TPM shifts
- Cost-saving potentials
- Measures
- Implementation
Assembly
Wire basket systems
- Process analyses in the welding lines
- Final assembly
- Final inspection
- Production data management
Door Line
Wood Industry
- Process analyses
- Determination of standard times
- Cycle time scheduling
- Layout and material flow planning
- Workplace design
Production
Lighting Technology
- Introduction of planned time systems for standard time determination
- Preliminary costing
- Production data management
- Setup time optimization
Final Assembly, Warehouse, Shipping
Musical Instruments
- Process optimization
- Workflow organization
- Organizational structure
- Layout and material flow planning
- Production planning and control
- Setup of assembly line
Paint Technology
Automotive Industry
- Production data management
- Layout and material flow planning
- Identification of savings potentials
- Implementation of measures
- Cycle time scheduling of flow production
- Process optimization
Fan Technology
Automotive Industry
- As-is analysis
- Plant comparison of national and international sites - standard times -
Mechanical processing
Automotive industry
- Production data management
- Final assembly
- Shipping
- Order picking
- Weakness analysis
- Improvement proposals
- Savings potential
- Process optimization
Assembly
Automotive industry
- As-is analysis
- Determination of standard times
- Savings potential
Assembly
Automotive industry
- Process analyses
- Determination of standard times
- Savings potential
- Production line takt time
- Measures
- Implementation
- SMD assembly
- Power setup
Assembly
Automotive industry
- Process analyses
- Determination of standard times
- Savings potential
- Measures
- Implementation
Organization
Automotive industry
- Production planning and control
Switchgear Technology
Automotive Industry
- Production data management
- SMD assembly
- Setup time optimization
- Implementation of planned time system
- Workforce planning
Injection Molding
Automotive Industry
- Production data management
- Setup time optimization in plastic injection molding
- Setup time optimization workshop
- Material flow and layout planning
- Weak point analysis
- Measures for process optimization
- Implementation
Injection Molding
Automotive Industry
- Master data in the ERP system
- Order processing
- Production planning and control
- Pre- and post-calculation
Organization
Wood Industry
- Production data management
- Final assembly
- Order picking
- Weak point analysis
- Improvement suggestions
- Process optimization
Final Assembly
Medical Technology
- Final assembly cycle time
- Workplace design
- Workforce planning
Final Assembly
Music Industry
- Production data management
- Identifying savings potential
- Material flow and layout planning
- Bottleneck analysis
- Measures for process optimization
- Implementation
Coating
Automotive Industry
- Production data management
- Layout and material flow planning
- Identifying savings potential
- Implementing measures
- Process optimization
Wire Basket Systems
- Production data management
- Process optimization
- Balancing cycle times in flow production
Industry Experience
See where this freelancer has spent most of their professional time.
Experienced in Automotive, Manufacturing, Food and Beverage, Healthcare, Aerospace and Defense, and Metals and Mining.
Business Area Experience
See which departments and functions this freelancer has contributed to most.
Experienced in Operations, Production, Quality Assurance, Supply Chain Management, Logistics, and Human Resources.
Languages
Statistics
Experience
Expertise
Profile
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