Products
One of the newest areas of business development is the professional approach to “automation and control”. The primary purpose of this consulting is to ensure that businesses operate in a stable, predictable, continuous, and efficient manner. This expectation is met by evaluating, developing, and managing various processes, systems, and system components. LENS Consulting Group is a leading market player in this innovative field.
An essential aspect of our work is that we do not believe in the traditional “automate everything” approach! In our work, we strive to achieve the perfect balance between human resources and automation, which we define together with our Client and, as a result, produce tailored solutions for each project. We can clearly see that a high value-added workforce remains essential in business life, and we pay close attention to this when designing systems and defining the degree of automation.
LENS has a unique role in the business world, as many companies around the world are involved in the automation of factories, companies, and businesses, but their development focuses on system design, procurement, and maintenance. The company is involved at a strategic level and, by defining an advisory role, it has an objective view. LENS assures its partners by seeing their business from ideal vantage points and through the sharpest of lenses. This ensures that LENS can spot serious threats, cost savings, and process acceleration options within a given workflow.
LENS Advisory Services
Following a strategic workshop with the Client, the first step of any project is the preparation of a status report, which provides a comprehensive and accurate map of the effectiveness of the company’s workflows and critical threats to the primary decision-makers. The status report will help you create a development plan that will provide you with details about how your business would operate most efficiently in terms of both time and cost. The development plan is strongly influenced by the unique requirements of the Client, and includes a cost plan that allows the Client to calculate the return on investment of development costs. LENS also performs this calculation at the request of the Client, which becomes an integral part of every development plan.
LENS, at the partner’s request, also supports the management of the complex development project and the project’s implementation within the organisation. This ensures that even a massive project can be executed effectively by the Client from a resource management perspective. In other words, LENS can define a sophisticated automation and control-based development that designed based on the Client’s needs and expectations.
THE MAIN STEPS OF LENS DEVELOPMENT
- Definition of business goals
- Evaluation of situation and identification of risks (based on consultation as well as personalised and requested information)
- Creation of a Status Report
- Strategic status presentation
- Definition of Development Policies (Based on Situation Review and Agreed Objectives)
- Definition of specific development goals and developing measurement methodology
- Preparation of an action plan (with every goal and consideration in mind)
- Creation of development action plans
- Making and launch of development project plans
- Evaluation of developments; definition of further action plans
The Current Market Environment
A business intent on producing quality products must contend with the demands of the global labour market. The recruitment, placement, and retention of a skilled workforce are a significant cost burden for businesses, and in many areas, turnover is increasing year over year. Thus, leveraging human resources poses a serious problem for growing businesses that seek both profit and quality.
For these reasons, the value of calculated and specialised automation has increased significantly. Bearing it in mind that human resources can only be reduced so much, there are growing needs for technologies, methodologies, and complex solutions that reduce labour demand and, at the same time, increase quality and cost-effectiveness, which in turn lead to increased profits. Automation is now a well-known and well-liked concept. Still, very few companies can design professional solutions, build applications, define the work needed, and manage business implementation. This is a new professional field that requires the highest standards of specialised knowledge and experience.
LCG CO-OPERATIONAL ROAD MAP
LENS always begins the collaborative process by exploring and defining the goals of the partner’s chief decision-maker(s) during an interactive workshop. There are clear requirements and standard processes in automation and monitoring, but they are only effective in practice if the specific development project is tailored to a partner’s particular goals.
Moreover, this transformation can only take place with a comprehensive understanding of the partner’s processes, which LENS gathers in a “Status Report”. In this report, LENS identifies the critical requirements and tasks necessary to achieve the partner’s goals. It highlights current operational gaps and areas of inefficiency. Also, it identifies those elements that constitute a concrete barrier to achieving client objectives. In other words, the Status Report, in addition to providing the partner with a comprehensive view of the effectiveness of their current business, clearly defines critical points for development.
Outputs of the Status Report:
During the Status Report phase, LENS prepares a presentation and presents it to the partner during an interactive workshop. After gleaning more informaiton from the partner during and after the workshop, LENS finalises the documentation and provides a brief, concise description of the consultancy work performed during this phase. LENS then produces an extended version of the Status Report, which covers all professional details and elements, and is a concrete development proposal that contains all strategic plans and specific calculations (financial and return plans, timely implementation proposals) in a complex and structured format.
LENS also supports the management in the complex development projects, the organising of an implementation process, and the operational management of the development process within the organisation, if required. This ensures that the partner achieves its primary goals and the implementation of the development plans yields maximum results.
Professional Background
The professional team at LENS Consulting Group has over 36 years of professional knowledge and experience. They have completed over 1,100 custom projects — including over 480 manufacturing technology developments — in which they rethought and implemented complex systems in small businesses, large enterprises, and multinational environments. The greatest value of our specialists is that they can adapt developments to the needs of the Client, as they have learned that although there are professional points that come to the fore in every project, there are no two identical developments in this area! The most crucial aspect for us is the balance between continuous internal innovation and stable, secure business.
With experience across various industries, LENS can provide its partners with truly thoughtful and sophisticated alternatives. Their tens of thousands of hours of field experience during commissioning and operational support is essential for setting realistic and measurable goals.
Our colleagues are specialists in the following areas
- Industrial process control
- Field instruments, sensors
- Electrical systems
- Manufacturing process development, LEAN methodology
- Production line mechanical modelling
- Mechanical design and optimisation
- Manufacturing efficiency analysis
As LENS scans the entire organisation and system, our solutions can range from installing simple field sensors to complex IT demands, if needed.
Expertise
Cost-effectiveness, market flexibility, sustainability, and reliable quality. Without these, there is no competitive auto industry. The diverse labour market and economic environment require the most comprehensive and state-of-the-art automation consulting services and IT tools such as IIoT and I4.0. By collecting and analysing useful information from production processes, LCG makes action plans and modifications that can have immediate, positive impacts on productivity and economic performance.
Changes in the labour market are not just a matter of scarcity: a reduction in production due to increased turnover and limited training capacity are pressing tasks that require system-wide solutions. Several technical solutions are available to resolve this situation, such as production automation, simplification and quality assurance of tasks, or even technology-supported, accelerated training processes; all of these can be a major step forward in increasing efficiency and productivity. Given all of I4.0’s capabilities, we also deal with security aspects. After all, production and security of supply are just as important as data protection. During complex consulting projects, we always look at the big picture; we combine operative demands with the ownership’s goals to yield the best possible result. We test, measure, recommend, and solve!
Security of supply, sustainability, energy efficiency, and economical power supply remain inconceivable in power engineering without a full level of automation. This is true not only during and after construction but also in the design phase. In order to provide a quality, stable supply for industrial and residential use, fine-tuned and fully controlled systems have to work like clockwork.
The complexity of energy projects is increasing rapidly due to ever-tightening environmental regulations and the proliferation of smart grids. The guidelines for the construction of a power plant must follow technical, economic, and legal rules. Remaining competitive in a constantly changing energy market is a challenge that requires an optimal solution. This is where the Lens Consulting Group can provide strategic support by recommending and implementing a variety of technologies based on the above considerations. Such support is not limited to the equipment forming the core of energy production (like boilers and turbines), but it also deals with the possible modification of auxiliary systems (fuel supply, preparation, flue gas treatment, heat recovery, etc.). For any modification, LENS provides projections of expected outcomes by using three-dimensional modelling and finite element method-based calculations.
Stable yield and efficiency without health risks; this result is only achievable via automation, from initial design to daily operation. Simulation and data processing can be the most powerful tools in agriculture. Given the many variables and risks inherent to the industry, excellent results necessitate not only the latest I4.0 and IIoT concepts, but also their proper application.
Machine learning, artificial intelligence, and well-organised production are essential for maintaining and enhancing competitiveness and profitability. This is exactly how Lens Consulting Group provides excellent, fully personalised solutions with proven, surgical precision. By taking ownership goals and attitudes into account, we help improve the company’s operations in every way. Thanks to a strong engineering knowledge base, we make only detailed and exact plans for improvements with the support of OPEX/CAPEX calculations.
Controlled quality, safety, efficiency, and cost-effectiveness; these are ensured by the appropriate level and method of automation. Automation based on strategies, accurate plans, detailed solutions, and clear KPIs help companies to make drastic improvements. This design- and support-focused automation is the core competency of LCG.
We pursue realistic, measurable goals together with our partners, and these shared goals are the cornerstone of any successful development project. This allows you to precisely control how and where your development is going to serve your company’s strategic goals. In addition to the capabilities of I4.0, we also deal with security aspects. After all, production and security are just as important as data protection. During complex consulting projects, we always look at the big picture; we combine operative demands with the ownership’s goals to yield the best possible result. Thanks to our accumulated industry experience, our unique multi-platform capability, and the work we have completed over the last two decades, we provide detailed, accurate solutions for every client.
CASE STUDY
PARTNER
Our partner has been a wholesaler of high-quality frozen products in the Central European market since 1989. They currently sell 1,037 products and have a complete range of frozen foods. As a major player, they periodically review and optimise their transportation processes.
DEFINED DEVELOPMENT POINTS
Based on a Status Report from a study conducted in 2019, we identified areas that could be further optimised for operation:
- The introduction of a well-vetted, barcode-based product tracking system, which has become increasingly critical due to a growing product portfolio.
- The migration of the stock documentation system from paper to digital, which has already begun but needs to be accelerated.
- In addition to basic knowledge, continued operations require advanced logistics training for employees due to the increase in the number and volume of deliveries.
ADVISORY AREA
Status Report, Planning, Execution
Our company has developed a detailed implementation plan for the aforementioned development points identified based on the Status Report, including design, procurement, implementation, training, follow-up, and periodic control.
PARTNER
Our partner is a printing company that has been operating in the Central European market since 1990. Their products include traditional printing products, from simple flyers to high-quality hardcover books and special packaging materials used in industrial applications. In addition to their well-trained technicians, their state-of-the-art technical background guarantees world-class quality.
ADVISORY AREA
Status Report, Planning, Consultancy
Our partner needed to move to a new factory to meet ever-growing customer needs. Important considerations when designing a new production plant include: having the right size, arranging the machinery as efficiently as possible, and making the move as quickly as possible.
Our company designed the optimal floor plan based on the Lean approach and demonstrated its advantages to the partner with the help of simulations. Thanks to this, the new plant has become much more efficient, and we were able to improve upon many previous processes via new machines.
PARTNER
Our partner, a company established in 1997 that has seen rapid growth, is a strategic partner and supplier of large multinational machine manufacturing companies. Its primary expertise is the production of specialised parts and tools. With a total floor area of 15,500 sqm, the partner utilises many modern innovations, such as welding robots.
DEFINED DEVELOPMENT POINTS
To help our partner maintain and strengthen its position with its clients, we embarked on a comprehensive development project, which was partly funded by a grant. Following the site visit, we identified several optimisable points in operation as part of the Status Report:
- There was no available information on the machines used in production, and there was no efficiency measurement system in place
- The accelerated migration of the product documentation system from paper to digital
- The software used throughout the process was inconsistent, some systems were incompatible with one another; some workflows were recorded and designed in Excel
ADVISORY AREA
Status Report, Planning, Consulting, Execution, and Implementation
The optimisation opportunities we discovered were mainly focused on providing a comprehensive view of the manufacturing process in a complex system. To do this, we designed a sophisticated software solution with a new network infrastructure plan, making sure that different types of machines could be connected to the new system, and we prepared the system for future upgrades. Most importantly, we prepared this entire process within a framework that led to a successful grant application.
PARTNER
Our partner is a major player in the international pharma sector and currently supplies active ingredients and products to 108 countries worldwide. The operation supports many member companies and subsidiaries with separate production, sales, and R&D departments. Because of the intense competition in this sector, efficiency is integral to the company’s success, so it reviews its operations regularly.
DEFINED DEVELOPMENT POINTS
Following the site visit, our Status Report identified two areas of improvement that would ensure significant profit growth:
- In many cases, the production efficiency required by the company itself was not attainable, but it could be significantly improved by re-designing and optimising the systems
- The standardisation of data collection for production lines, equipment, and machines
ADVISORY AREA
Status Report, Planning, Schedule Preparation
LCG developed a detailed system plan and timetable for the development points identified in the Status Report. Based on this, plans have been submitted to establish an OPC Data Collection Network, which is currently being approved.
PARTNER
Our customer is an internationally renowned healthcare provider with a presence in 64 countries. They have three subsidiaries in Hungary alone that employ 3,483 people in 2020. To meet the increased market demands, the company is working on establishing a new factory in Hungary, which will mean a larger volume and new product lines for domestic production.
DEFINED DEVELOPMENT POINTS
In addition to a site visit focusing on current processes, the planned production line also received special consideration in the Status Report. The following are the main points elaborated in the workshop held after the Status Report:
- We recommended upgrading the current production line, including the replacement of many machines.
- The replacement of QC class assets has become necessary due to extra tasks.
- Increased space in revised plans for the new R&D unit and microbiology laboratory — our analyses concluded that they received significantly less space than in the original design of the units.
- Throughout implementation, optimisation of connection points and utility demands has also become crucial.
ADVISORY AREA
Status Report, Planning, Construction Preparation
LCG developed a detailed schedule for replacing the machines in the existing plant with a focus on efficiency and reliability. In the new plant, precise connection points and locations have been specified, tailored to the optimal productivity, and we have designed and visualised the complete equipment, furniture, and engineering of the QC, R&D, and microbiology labs according to the customer’s requirements and the most efficient layout.
PARTNER
Our partner is a food industry company that has been operating in Central Europe for 27 years. They process and package fresh FMCGs using grading, washing, drying, and packaging equipment. The company’s focus is to set itself apart on the market with healthy and fresh products at all times, all while continuously improving its products and food safety standards.
DEFINED DEVELOPMENT POINTS
We partnered with this client with the express goal of increasing their efficiency. Following the site visit, the Status Report revealed the potential for improvement in the following areas:
- They could not extract data from their current production line, so they had no information on efficiency, water usage, or energy consumption. Instituting defined measuring points has become essential, especially due to the expanding nature of their product portfolio.
- Heat distribution, which is necessary to maintain high quality, was not uniform during production.
- The water mixing process could not be regulated at a high level.
ADVISORY AREA
Status Report, Planning, Construction
LCG developed a detailed implementation plan for the development points identified in the Status Report. As part of this, a ThingWorx platform for data collection was built into metering devices, which were then integrated into the plant’s systems. Moreover, we planned a PLC system for control of the water mixing process, which we also incorporated into ThingWorx system, and we instituted temperature control supported by MPC methodology.
PARTNER
Our partner is a trading partner of multinational companies that offers complete solutions to their food industry customers, from food processing systems to filling lines to beverage/carton packaging.
DEFINED DEVELOPMENT POINTS
One of the building blocks of efficiency — the relationship and communication between management and employees — needed improvement. Recognising their weakness in this area, our partner asked us to organise the gathering of ideas from employees, who were constantly coming up with improvements.
Solution (methodology):
- On-site tour
- Understanding processes
- Develop a reward system
- Web interface design and development
- Automatic design and installation
- Designing and implementing a reward and compliment card system
ADVISORY AREA
Status Report, Planning, Consulting, Construction.
After reviewing the processes, we have developed an optimised web-based system through which employees can submit their suggestions and feedback to senior management; senior management could then reward employees with points, which employees could redeem as gifts. In addition, suggestions were saved and organised in a database to facilitate later usage.
PARTNER
Our partner has world-class industry expertise and experience in industrial and mobile hydraulics, linear actuation and assembly technology, electric drives, and controls.
DEFINED DEVELOPMENT POINTS
The company is dynamically evolving year by year, and its company processes could not keep up with this growth, so the much-needed expansion of a production facility provided the opportunity to rethink its production layout and processes.
Solution (methodology):
- Create a current state map of the value stream
- Define development potential
- Create a future status map
- Create a Lean/Kaizen vision
- Define development sub-projects
- Draft a comprehensive development plan (12-24 months)
- Predict goals and results
- Address resource planning needs
ADVISORY AREA
Status Report, Planning, Consulting, Construction.
Based on the Lean Management approach, we explored the current state of company operations with our senior management. During the development of the current state value flow map, LCG identified several potential areas of development that could guarantee the reduction of ongoing losses.
While drawing the future status map, we created a guideline for Lean development and defined related sub-projects. We prepared a comprehensive development plan, in which we analysed and planned the achievable goals and the necessary resources. The result of this analysis is well suited to the continuous development of the company and the preparation of the next steps in digitalised production. Indeed, the revenue and profit growth the growth achieved through these improvements was made quantifiable
PARTNER
Our partner has powerful brands, innovative technologies, and extensive experience in the printing, packaging, office supplies, bookbinding, and paper processing industries.
DEFINED DEVELOPMENT POINTS
The machine control software developed for the company did not work properly, and because of this constant malfunctioning, there were delays that impacted various lines of business. Thus, important resources had to be spent on troubleshooting, with significant loss of revenue, profit, and market share. The projects involved many machine lines in several countries across multiple continents. Various versions of programmes running on production lines further increased operational difficulties. We had to unify these challenges and provide the optimal transnational solution.
ADVISORY AREA
Status Report, Planning, Consulting, Construction.
We built a complex understanding of current processes following the review of user manuals, Excel flowcharts, the complex wiring diagrams, and reference programmes. With this understanding, we unified the structure of the programme, defined new programme points, and reprogrammed key functions. The system now functions seamlessly across continents, freeing up time for our partner to tackle more significant business challenges.