Lean Transformation in One-Off Production. Strategies for Process Optimization

This master thesis explores the application of PULL production control tools to optimize the manufacturing process in the mechanical department of an Engineering-to-Order (ETO) company. The study focuses specifically on the one-off production of roll forming rollers, a process characterized by high variability and complex workflows. The goal is to enhance efficiency by reducing lead times, minimizing inter-operational inventory, and streamlining production flow while ensuring flexibility and quality. The research follows a structured methodology. First, it establishes a theoretical foundation by analyzing Lean Manufacturing principles, Value Stream Mapping (VSM), and production flow management strategies suitable for low-volume, high-mix environments. This framework is then applied to assess the current state ("As Is") of the production process, identifying key inefficiencies such as excessive work-in-progress, long waiting times, and unbalanced workloads. Based on this analysis, a future state ("To Be") VSM is developed, envisioning an optimized process with FIFO buffers, reduced batch sizes, and single-piece flow to improve responsiveness and eliminate waste. A transitional phase is introduced to ensure a gradual and sustainable implementation. This study demonstrates that Lean methodologies are effective even in one-off production settings, enabling structured improvements without compromising customization. The findings offer a practical roadmap for companies seeking to implement Lean principles in highly variable production environments, enhancing both operational performance and adaptability.