Beyond Optimisation

Where optimisation ends – real performance begins

For leaders in production, supply chain, and distribution seeking structural impact instead of local optimisation.

You’ve optimised a lot, but the real lever is missing

Your organisation is stuck in a structural paradox:

Optimisation reinforces the existing system while postponing real change to tomorrow.

Optimisation looks for compromises that aren’t actually necessary

You can remove the very foundation of optimisation by resolving the goal conflicts that keep occupying you endlessly.

Lean vs. robust. Availability vs. capital tied up.

Resolved conflicts create degrees of freedom

Production and supply chain are not efficiency problems – they are control problems driven by chronically optimised goal conflicts.

Doing more of the same delivers diminishing returns. True performance leaps only emerge from new degrees of freedom.

Results

Unachievable through optimisation – standard with breakthrough solutions.

15-45%

Output & Productivity

30-60%

less

Inventory

40-80%

shorter

Lead times

50-99%

less

Late Orders

30 years of experience

We are the architects of production, control, and improvement systems for:

Festo (EOO)

Sigvaris (PULSE)

Resideo EMEA (OC6)

Honeywell ECC EMEA (HRP)

Case Studies

Festo AG & Co. KG

At Festo, our solution is known as Engpassorientierte Organisation (EOO, English: Constraint-Oriented Organisation). It was implemented by our team at the Rohrbach plant and continues to serve as a key strategic pillar for the further development of the Festo Group.

✔63% less backlog
✔50% less backlog depth
✔38% higher capital turnover
✔56% shorter plant-wide lead times
✔39 percentage points higher availability across selected product families
✔100% higher revenue growth compared to the sister plant

Honeywell

Within just six months, we turned the Mosbach plant into the European benchmark of the group. Our solution at Honeywell is called Honeywell Replenishment Planning (HRP). It is regarded by management as a “game changer” and has since been rolled out across all major Honeywell plants in Europe.

✔51% lower inventory
✔20 percentage points improvement in delivery reliability (from 74% to >94%)
✔38 (!!) Inventory Turns at finished-goods level, across more than 6,400 SKUs with immediate availability

Wittenstein SE

There was a clear objective: to increase output in the constraint areas as quickly as possible. Working closely with the customer team, we achieved the following without adding additional personnel:

✔Development and implementation of a customer-specific planning, control, and improvement solution within just 6 weeks
✔40% (!!) higher output within just 4 weeks of go-live.

Peha

Initial situation: Severe delivery problems with frequent customer escalations. Objective: Rapid and sustainable improvement in delivery performance while simultaneously increasing output. Results:

✔after 4 weeks: 79% less backlog
✔after 8 weeks: 70% higher plant-level output
✔after 9 weeks: 80% fewer customer escalations
✔100% planner confidence of doing the right thing

Sigvaris AG

The objective was to introduce a new production system capable of meeting the growing demands of the export business. At Sigvaris, our solution is called PULSE. The objectives were achieved with Swiss precision:

✔41% shorter lead times
✔31% higher inventory turns
✔99% less backlog

Since 2021: Expansion of the collaboration with Sigvaris USA & Canada

Since 2025: Expansion of the collaboration with Sigvaris Poland and France

Resideo

One of our largest clients. A digitally integrated supply chain with aligned priorities across all production levels and sites. Our solution at Resideo is called OC6 – it plans and controls the entire supply chain, spanning 5 production plants and 8 warehouses across 7 countries.

✔30% – 65% lower inventory
✔30% – 79% less backlog
✔up to 80% fewer late order line items

Your Expert

Thomas G. C. Hummel

MANAGING DIRECTOR & CO-FOUNDER

Dipl.-Ing.: in Industrial Engineering, TU Berlin, Focus: Production Planning and Control

TOC-Expert: All TOC applications trained by Eli Goldratt and Alex Mesahr at the Goldratt Institute

Author: Total Quality Management

Project Lead for Eli Goldratt on multiple TOC projects

Managing Director A. Goldratt Institute (NE) BV, Germany

Founding Partner Goldratt Implementation Group Europe

Managing Director & Co-Founder OneChain GmbH

Architect of planning, control, and improvement systems for Festo, Honeywell ECC EMEA, Resideo EMEA, and Sigvaris