Operational Excellence – Roto’s Production System

With the Road to Operational Excellence (ROPEX), Roto Frank Window and Door Technology (Roto FTT) aims to achieve operational excellence through lean processes and continuous improvement, Dr. Stefan Thiemermann, Director Global Operations at Roto FTT, explains: “ROPEX is a production system which links our strategic goals with operational excellence.”

ROPEX is more than an optimization initiative. Thiemermann emphasizes: “It is our value proposition to our customers: stable processes, high quality, high delivery reliability, and group-wide sustainability goals. This creates real added value for our customers.” The system also promotes flexibility, efficiency, and innovation within the global production network.

A key element is the Kaizen concept of continuous improvement in small, yet effective, steps. Improvement routines systematically analyze problems, test solutions, and standardize measures. Stephan Strohbuecker, Head of Production Management & Technology at Roto FTT, adds: “Our goal is to implement improvements faster and achieve measurable results.”

Implementing ROPEX requires a growth-oriented mindset where managers function as role models, drive change, and motivate their teams to perform at their best. “Good leadership is the key to success. We take responsibility and strive for continuous development and improvement for ourselves and our employees,” sums up Thiemermann.

The production system combines coordinated principles, methods, and tools to establish a strong foundation for a high-performing value chain. Quality, cost, time, and sustainability are crucial for Operational Excellence.

At its core, the system is built on four fundamental pillars: zero defects, value stream focus, agility, and clarity. These are supported by a culture of continuous improvement through Kaizen and empowered by strong mindset and leadership.

Each of the four principles is linked to specific methods, tools, and best practices. The zero-defects approach aims to achieve robust processes, autonomous quality, and preventive error avoidance using the Poka-Yoke method. This is not only applied in Roto production, but also in the upstream product development process. Value stream orientation focuses on a waste-free flow of materials and information – from customer inquiry to delivery. Agility means being able to flexibly respond to market changes. This is achieved through interconnected systems, consistent control, and by balancing capacities and cycle times in continuous production. Clarity represents a safe, ergonomic work environment, visual standards for detecting deviations, and transparent communication.

Strohbuecker emphasizes: “ROPEX is not a rigid system, but a dynamic set of different methods and tools. These must be utilized in conjunction with each other to create a solid foundation for continuous improvement.”

The global ROPEX initiative project team includes local and regional plant managers and experts, as well as global processes managers based at company headquarters in Leinfelden-Echterdingen. “All 18 plants operate according to the same principles, creating transparency, comparability, and a common language in production,” summarizes Thiemermann.

With ROPEX, Roto FTT has set up a practical production system which is based on proven lean principles yet tailored to Roto’s specific requirements. It combines strategy with practice, management with culture, and methods with impact. The path to Operational Excellence is clearly defined and actively advanced every day.