Services
Ramp-up management.
Between the first approval and stable series production, it is decided whether a project meets its goals. We manage the ramp-up of new plants, lines and products – with clear milestones, measurable KPIs and a team that solves problems at the root cause.
When you need support during ramp-up
- A new plant or line has to reach target capacity on schedule.
- Scrap, downtime or rework are slowing the ramp-up.
- Process repeatability and reproducibility are not stable.
- Start of production is approaching, and the plan is shaky.
What we take on
- 01
Ramp-up planning
Milestones, capacity stages and acceptance criteria from start to target performance.
- 02
Process capability
Root cause instead of symptom: stable, repeatable processes with Lean Six Sigma methods (DMAIC).
- 03
Quality and approvals
Quality management, initial sampling and customer approvals – including in regulated industries such as medical devices (ISO 13485).
- 04
KPIs and controlling
Scrap, equipment availability, on-time delivery: every production day becomes measurable.
- 05
Team and shift model
Qualification, roles and shift organisation for full-load operation.
- 06
Handover
Documentation and knowledge transfer, so performance is sustained after we leave.
How a ramp-up works
- 01
Preparation
Ramp-up plan, criteria and responsibilities.
- 02
Initial production
First series parts, sampling and approvals.
- 03
Capacity stages
Step-by-step ramp-up along the capacity curve.
- 04
Stabilisation
Process capability, scrap and availability on target.
- 05
Handover
Knowledge transfer to the team on site.
How to recognise a good ramp-up
- 1Start of production happens on the planned date.
- 2Scrap decreases measurably with each capacity stage.
- 3KPIs are collected and reviewed daily.
- 4Problems are solved at the root cause, not reworked.
- 5The local team runs operations on its own after handover.
Projects from practice
All case studies
Start-up & plant construction
Start-up in an emerging market
Automotive supplier, Mexico
- Result
- SOP on time, scrap ≤ 2.5 %
- Duration
- 18 months
Lean & cost
Quality and delivery dates under control
Medical device manufacturer, Switzerland
- Result
- Scrap ≤ 1 %, 95 % on-time delivery, 7 % cost reduction
- Duration
- 12 months
Start-up & plant construction
From greenfield to series in 18 months
Textile producer, Eastern Europe
- Result
- Launch after 18 months, defect rate ≤ 3.5 %
- Duration
- 2 years
Frequently asked questions
What is ramp-up management?
The systematic management of a production launch – from the first series part to stable target capacity. It includes ramp-up planning, process capability, quality, KPIs and team qualification.
How long does a ramp-up take?
That depends on the product, industry and maturity of the processes. What matters is a plan with fixed capacity stages and acceptance criteria against which progress can be measured every week.
Which KPIs matter during ramp-up?
Scrap and rework rates, equipment availability, on-time delivery and progress against the planned capacity curve.
Do you also support ramp-ups in regulated industries?
Yes. Dr. Wolf is a certified internal auditor for ISO 13485 and has led quality and ramp-up projects at medical device manufacturers.
Let's talk about your project.
A first conversation clarifies the task, expectations, time frame and budget – openly and confidentially.