Crisis management and solutions for value creation in manufacturing companies
Sustainable Operational Excellence
Analytical, structured, and hands-on, OPEX RESULTING delivers stabilization and optimized value streams by adapting management, organization, and processes – with a focus on delivery capability, productivity, sustainable results, and the people within the company.
Productivity increases of up to 200%
Over 100 projects worldwide
Up to 2,500 employees in the project environment
Over 15 product development & industrialization projects with OEE SOP +3 months>75%
Reliably completed interim management mandates since 2023
Services
Individual solutions for manufacturing companies
Interim Management
COO, Restructuring, General Management Operations, Plant Management, Turnaround, Portfolio Management, Manufacturing & Industrial Engineering, Change Management, OPEX Management, Project Management.
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Multi-site & worldwide assignments possible. OPEX RESULTING is interculturally prepared and experienced, integrates seamlessly, and is fluent in German, English, Spanish, and French.
OPEX RESULTING also offers the assembly of problem-solving interim management and specialist teams and leads the interim team task in a federated capacity.
Fixed-term employment contracts possible.
Placement of Experts & Interim Managers
Placement of suitable profiles for your project from the OPEX RESULTING partner network for all areas of a manufacturing company.
Process Optimization / Task Force
Quick Check, Implementation, Delivery of Results
Problem identification and solution for OEE, capacity, productivity, quality, shop floor efficiency, shop floor management, maintenance, production planning, factory planning, logistics, production planning and control, quality assurance, project management
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Project Management & Governance PMO
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Operations Due Diligence
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Product Creation Process & Industrialization (Greenfield, Brownfield, Relocations)
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Multi-project Management
- Automation, productivity, and quality improvements
- Operational Due Diligence (M&A)
- Creation, installation & optional hosting of project governance, e.g., guidelines, project management tools & Project Management Office (PMO)
- Change & Transformation (Footprint, Culture, Technology, Product, Strategy)
OPEX RESULTING has project management tools ready that are adaptable to any project. We start productively and master communication, collaboration, and cooperation.
EBITDA Optimization
OPEX RESULTING delivers meticulous:
Fact-based analysis, definition & quantification of potential EBITDA improvements, risk assessment for investments & possible measures, strategy creation & value-oriented immediate action planning with roadmap, leadership in the implementation of measures
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Benefit especially in crises, company acquisitions, or sales.
Production Systems
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Strategy formulation, setup, optimization, technical measures, organizational development, Lean method training, Train-the-Trainer, roll-out, hosting, academy, lighthouse projects, culture, awareness, audit, Lean assessments, KPI
OPEX RESULTING involves these areas in a measured way that promotes day-to-day business: Production, Development, Production Planning, Production Planning and Control, Customer Service, Intralogistics, Maintenance, Mechanical Engineering, Toolmaking, Productivity and Quality Optimization, HR, Development, Controlling, Works Council, Representative Body for Severely Disabled Persons, etc.
Know-How Protection & Development
Knowledge of critical procedures, recipes, and causal chains in production operations evolves and resides primarily in the minds of employees. This has fatal consequences for operational results if these people are no longer there.
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Based on value-stream and process-oriented good-practice solutions, OPEX RESULTING sets up digital and analog knowledge protection that is easy to update, expand, and transfer to other users. A specific KPI-based update methodology, active know-how bundling methods, and the formation of networks (including international) are practical examples of our service.
We link the qualification matrix, HR processes, and process matrix into an effective and motivating dynamic of value protection. This ensures successful generational changes and multi-skilling, as well as survival through high turnover storms.
Reaching the goal in a few steps
Initiation
Free initial consultations by phone and preferably on-site (travel costs calculated for journeys over 100 km), including one-hour consulting and decision-making aid for delicate strategic choices. Legally compliant offer within 12 hours after project clarification.
Analysis & Goal Definition
At the beginning, existing processes, structures, and operational challenges are analyzed. Together, we define clear goals, potentials, and concrete fields of action.
Measures & Operational Implementation
Based on the analysis, practice-oriented measures are developed to improve productivity, quality, cost structures, and cooperation – directly adapted to your organization.
Sustainable Stabilization & Further Development
The developed solutions are sustainably anchored in the company so that improvements remain effective in the long term and Operational Excellence becomes part of the corporate culture.
About Us
Operational Excellence with experience, responsibility, and vision
In management positions in Europe, America, and Asia, he was responsible for turnarounds, productivity increases, plant setups, relocations, production systems, and complex transformation projects – always with a focus on sustainable results and the people involved.
As an interim manager and implementation consultant, Johannes has been securing and improving the operational results of his customers since 2023.
International Experience & Operational Implementation
Practical Operational Excellence from international industrial and production projects – from strategic planning to operational implementation directly at the plant.
Result-Oriented Interim and Project Management
Call, project clarification, deployment. Immediate situational assessment and assumption of responsibility without wasteful onboarding, with harmonious integration into existing organizations followed by stabilization and optimization – that is my expertise from numerous task forces and turnarounds.
Focus on People & Cooperation
Sustainable improvements only occur where people, know-how, and functioning teams are actively involved and further developed.
Holistic solutions instead of isolated measures
OPEX RESULTING combines processes, organization, and operational implementation into sustainable solutions with a measurable impact on productivity, quality, and profitability.
Success with clear values
Mission
Possible! OPEX RESULTING follows its vision through the dynamic creation and renewal of our own processes to make Operational Excellence easily usable and result-oriented for our customers and ourselves.
Vision
Operational Excellence is a matter of course and a joyful mindset. It is easily tangible and accessible to everyone. The goal is a healthy interplay of people and processes for a livable, natural, and prosperous world.
Values
Sustainable interplay of economy, ecology, society, and cultures through waste-free operations, promotion of the common good, appreciation, cultural diversity, moral courage, love, family, friends, hospitality, commitment to performance and discrimination & mediocrity
What customers & companies say
“… understands to an extraordinary degree how to bring together diverging interests for the benefit of a common goal.”
“High reputation in a wide variety of production plants worldwide through professional problem-solving behavior and intelligent implementation proposals”
“Balance between a structured approach and pragmatism”
“Comprehensive specialist knowledge of production systems, experience, and capability for the implementation of production systems”
“Extensive methodological knowledge for the implementation of the CIP process”
“Competent representative in other functional areas such as sales, HR, or works council”
Production Systems
ZF Friedrichshafen AG, 2008
“Lead from the front mentality was crucial as the organization faced new challenges”
“Hands On approach filling the voids of an operational infrastructure still requiring improvements until meeting the challenge and the strengthened organization”
“Strong technical background, proven management record and contagious enthusiasm”
“Highly effective leader at our company”
Operations Management
Larry Carlson, General Manager, Carcoustics USA, Inc., 2005
“Activity resulted in an up to fifty percent increase in delivery volume, which led to the complete elimination of accumulated backlogs by the end of his tenure, despite continued high demand.
Mr. Pfleger achieved this through a variety of measures that he placed within the team and whose implementation he consistently pursued. He was not above lending a hand himself wherever necessary. He also introduced proven tools and applied them appropriately within the company context.
… inspires and motivates employees even in times of high workload. His demeanor is always clear, convincing, and consistent, yet without personal attacks.
… was able to familiarize himself with the technical and organizational matters of the company in a very short time.
… made a significant contribution to the reputation of our company with internal and external customers as well as employees.”
Operations Management
Mathias Köhler, General Plant Manager, ZKW Elektonik GmbH, 2023
“Excellent and, in peripheral areas, very deep specialist knowledge, especially in the areas of operations and industrialization”
“High degree of social competence, very great ability to integrate”
“Exclusively excellent solutions for all occurring problems”
“Consistently positive feedback from the OEM”
Project Management PCP & Industrialization, Large-Scale Projects
ZF Friedrichshafen AG, 2021
“Successful plant manager.
Management of large relocation projects and new e-mobility projects.
Great international expertise.
Sound process knowledge, especially in the area of the production system.”
Operations, Turnaround & Change Management
Rainer Mohr, VP Reporting Unit, ZF Friedrichshafen AG, 2023
“Desired changes through proactive thinking and action paired with a hands-on mentality”
“Generating high performance in the relevant teams”
“High empathy and team-building strength”
“Integration of project management and operational series readiness into a successful ramp-up”
“Solution-oriented conflict resolution involving customers”
“Successful project work in a short time with know-how development through the selection of suitable employees and their professional induction”
PMO, Project Management, Organizational Development
Stephan Schmees, Managing Director, DIRKS Industrial GmbH & Co. KG, 2022
“Effective solutions for difficult problems”
“Successful practical implementation”
“Influential setup and standardization of a global production network with footprint optimization (relocations, turnarounds, performance improvement) and seven production sites involved worldwide”
Operations, Turnaround & Change Management
Claus Umnus, President Product Line, ZF Friedrichshafen AG, 2020
Our Customers
SERO EMS Group
Our Customers
360dt
Carcoustics
DIRKS Group
Philips
SERO EMS Group
ThyssenKrupp
ZF
ZKW Group
Poppe + Potthoff GmbH
ZF-Foxconn
FAQ
Frequently Asked Questions
Can I join?
Working together as a partner also makes sense. Use the contact form under the Contact menu item.
Which Lean Production methods does OPEX RESULTING apply?
Lean (Extract): KAIZEN, CIP, 8D, A3, VSA, VSD, 5S, JIT, JIS, SMED, Line Balancing, TPM/Predictive/Preventive Maintenance, 6Sigma, Zero-Defect, Poka-Yoke, Andon, Standardized Work, ergonomic methods, load handling, Visual Management, HSE processes, Milkrun, AGV, Pull, Mock-Up, KATA, Lean Assessment, Benefit Analysis
What competencies does OPEX RESULTING have?
Leadership & Departments: Day-to-day Operations Management, Strategic and Operational Planning, Business Planning, Change Management, Production, HSE, Manufacturing Engineering, Industrial Engineering, Factory Planning, Relocations, Logistics Management, Quality Management, Supply Chain, Launch Management, Automation, Digitalization, Maintenance, Toolmaking, Investment Planning, P&L, Controlling, Cost Accounting, Calculation, Small and Large Series, Business Development
Interface Management: Task Force, Compact KPI System & reporting, OEE deep drill, Shopfloor Management, QKLSM, Customer-Supplier Management, Supplier Development, Level Talks, Go & See & Imerge, Idea System, Fast Teams, Auditing, Layered Audits, Balanced Score Card, MES/MOM, SAP
People & Interaction: Conflict Management, Multi-skilling, Aging Workforce, Human Group Processes, Works Council Negotiation and Mediation, Coaching, Change Management & Organization, Leading in the Matrix, Personnel Planning, Organizational Development, Crisis Management, Production System, Intralogistics, Global Production Network
Lean (Extract): KAIZEN, CIP, 8D, A3, VSA, VSD, 5S, JIT, JIS, SMED, Line Balancing, TPM/Predictive/Preventive Maintenance, 6Sigma, Zero-Defect, Poka-Yoke, Andon, Standardized Work, Ergonomics, Load Handling, Visual management, HSE processes, Preventive Health Protection, Milkrun, AGV, Commissioning, Replenishing, Fulfillment, Mock-Up, KATA, Lean Assessment, Train-the-Trainer, 4MAT, Benefit Analysis
PCP/Project Management/Project Governance: Frontloading, DFMA, Design-to-Cost, Design for 6Sigma, MaB, Rapid Prototyping, QFD, DOE, FMEA, Value Analysis, Feasibility Study, APQP, PPAP, RG, Run@Rate, Lean Process Design, Factory Planning, Zero Emission, Creativity Tools, C8s, Project Management Tool, Risk Management, Guidelines Location Setup & Product/Process allocation, Factory Scalability, Impact reaching Lessons Learned, Training Center, Problem Analysis and Solution, Supplier selection, Operational Due Diligence, Engineering Change Management Standards
Certifications: ISO9001, ISO 14001, TS16949, TISAX, Q1
Which production technology & processes is OPEX RESULTING familiar with?
Assembly, PCB production, testing processes (function, presence, position, location, tightness, material/product properties, dimensions, imbalance, color, contours, ultrasound, image processing, cleanliness), 3D plastic printing, metal forming, heat treatment, surface treatment, powder coating, KTL/ATL coating, cutting, plastic injection molding, vacuum forming, gluing, wetting, waterjet cutting, vapor deposition, welding processes (disk laser, MAG, friction, ultrasound), riveting, rolling, machining, winding, pressing, drawing, shot peening, robotics, CNC, image processing, handling technology, AGV, mechanization, hydraulics, electric drive manufacturing, transport and conveyor technology, testing technology, information and communication technology, PLC, MES, SCADA, PPS, worker guidance, VR/AR, traceability
Which product environments is OPEX RESULTING familiar with?
Drive components // Stator, rotor, torque converters, clutches, dual-mass flywheels, automated manual transmissions/electromechanical actuators, release bearings, master and slave cylinders
Interior & Engine Compartment // Headliner, trunk side trim, load floor, parcel shelf, carpet, sun visor, door seal, hoodliner, beauty cover, engine encapsulation
Electronics // SMT, Control Units, LED headlight modules
Let’s do it
Get in touch with us now. We look forward to your message and will be happy to advise you personally.
Mon – Fri: 9 AM – 5 PM | Sat: 10 AM – 12 PM | Sunday closed
