The "breathing factory" - rethinking flexibility and efficiency
How does this model work in practice? Which sectors benefit from it in particular? And which technological innovations ensure measurable improvements? Alphonse Stremler answers these and other questions in our interview.
What is the concept of the "Breathing Factory" and what are the main objectives of this model in industrial production?
Alphonse Stremler:
In today's world, it is necessary to significantly increase productivity in order to remain competitive. Rising costs (raw materials and production factors) in high-wage countries are forcing us to increase productivity disproportionately. Many companies are currently not running smoothly and sales are falling sharply in some sectors.
The balance between supply and demand when markets fluctuate is now partially offset by building up inventories, which in turn carries high risks in terms of financing and possible write-offs.
The "breathing factory" solution creates high flexibility and high productivity. Output must be "breathed" promptly so that production can be quickly adjusted at any time, e.g. in the event of a drop in orders.
With our approach, you can control these waves precisely. The entire supply chain and production are adapted cost-efficiently. The "breathing factory" flexibly follows every market development.
Continuous growth doesn't really exist. That's why we trim companies/productions precisely for cost efficiency. The focus is on customer orientation, particularly with regard to delivery times and delivery quality at low stock levels.
We control precisely, cost-optimised, quickly and flexibly - that is the breathing factory.
How do you realize this in concrete terms?
Alphonse Stremler:
Firstly, we optimize the process and information network. As part of this, we also increase the performance of the machines and systems (overall equipment effectiveness (OEE) and output per hour (PPH)).
Due to these highly efficient production steps, the planning is linked to the specific market requirements.
We enable your company to generate planning data that guarantees optimum performance management in your production and information network.
The special feature of our range of services is that, by implementing simulation-based, discrete-event planning and synchronisation systems, we are able to control this optimum performance via the planning process at the highest level.
This holistic approach offers a unique combination of technological innovation and strategic process improvement to successfully meet the challenges of modern production environments.
The "Breathing Factory" is also characterised by a new level of precision in planning: Instead of average data, real data is used in real time to optimally take into account dynamic dependencies and interactions between processes, resources and restrictions. This eliminates unnecessary time buffers and gives companies a clear overview of what is currently happening.
A value-added chain optimised by STREMLER works at the production optimum - a factory is designed for maximum performance and we believe that this capacity must also be utilised. We implement this consistently.
Which industries benefit most from the Breathing Factory and what are the industry-specific requirements?
Alphonse Stremler:
The "breathing factory" offers considerable advantages in all branches of industry, especially in sectors with low margins and high competitive pressure.
For example
Food industry: Raw material costs are rising and customers are demanding a wide range of variants. With the resources available, we achieve an increase in productivity of 20-25% while at the same time reducing stocks by 30-40% and achieving a delivery reliability of 99%.
Automotive and series production: Despite missing parts and unforeseen events, we provide a process, data and planning platform that ensures agile production at an optimal performance level. Our technology ensures 100% parts availability. You will achieve productivity increases of > 20-25%, shorter throughput times in the demand flow with a 50% reduction in stocks and an increase in delivery capacity (OTIF).
Machine/plant construction: We ensure precise control at the individual component level and guarantee availability by means of a generic, multi-level planning process that ensures the monitoring of parts with long lead times. Material flow is controlled precisely according to delivery dates. The results achieved are a 20-25% increase in productivity, with a >50% reduction in inventory levels and an >80% reduction in lead times.
Textile industry: This approach provides the flexibility and precision needed to ensure the continuous renewal of collections, while also maximizing productivity. We synchronize demand with retail requirements, while ensuring 99% availability (NOS) and customer-specific service from the flow of goods. Project results: 30-40% reduction in working capital. Drastic reduction in write-offs.
(Note: further industry references can be found here: )
