Lutz Dahlke

Lutz is a very experienced and qualified lean consultant with a successful corporate career in GKN and Federal Mogul. He specializes in building sustainable systems via engaging employees in applying the situationally right Lean tools and in optimizing both material and information flow.

He had direct line responsibility for creating lean structures for the first time at plant level and used them both in the manufacturing and in the administrative area. 

EXAMPLE RESULTS:

  • From 27 days to 2 days lead time reduction

  • 40% reduction in WIP

  • Reduction in  backlog from more than €3 million to €0

  • Reduction in special freight from €200,000/month to €0

  • 40% productivity increase freeing up an entire shift of 15 employees

  • Total elimination of semi-finished stocks  by improving process stability and material flow

  • 45% increase in OEE on bottleneck machines

PROJECT EXPERIENCE:

  • Introduction of production systems

  • Optimization along the value chain using value stream mapping and design

  • Set-up time reductions using SMED

  • Technical optimizations to eliminate bottleneck processes

  • Building effective team structures

  • Introduction of auditing systems for lean tools (5S, LTA, VM, SW, Kaizen, TPM)

CONSULTING SKILLS:

  • Lean Enterprise

  • Optimisation along the value chain using value stream mapping and -design

  • Business Process Excellence / Improvement

  • Technical optimisations to eliminate bottleneck processes

  • Employee involvement and development systems, Building effective team structures

  • KANBAN and FIFO scheduling

  • Introduction of auditing systems for lean tools (5S, LTA, VM, SW, Kaizen, TPM)

  • Visual management implementation

Anthony Collins