Foreast Consulting

Costs

Cost reduction through cost drivers: cut the causes, not investments in development

Costs · 5 min read · 26.10.2026

Across-the-board cuts by cost center often fail, because they cut the cost statement, not the causes behind the costs. We show cost drivers — where costs actually arise — and how to measure and manage them.

Cutting 14% Downtime: How a Weaving Mill Handled Growing Demand Without Buying a New Machine

Costs · 3 min read · 02.09.2026

In a weaving mill running seven days a week, we reduced unplanned stoppages by categorizing downtime and introducing autonomous maintenance — growing demand was managed without purchasing a new machine.

Scrap at 6.5% cost half a million a year: how an injection molding plant made hidden costs visible

Costs · 3 min read · 21.10.2026

At an injection molding plant, scrap was reported in kilograms, so nobody knew what it cost in money. By measuring scrap by press and by shift, we uncovered hidden costs of half a million euros a year and differences between shifts of up to 4%.

Changeover from 45 to 12 Minutes: How an Engineering Company Cut Costs Without Layoffs

Costs · 4 min read · 29.07.2026

An engineering company with 240 employees was losing margin on small batches — long changeovers, overtime and a 4.2% scrap rate. The project paid for itself in five months: changeover time fell to 12 minutes and scrap dropped by 38%.

Topics

Courses

Lean Manufacturing — Fundamentals

Efficient Production — SMED, TPM and OEE

Cost Reduction Without Endangering Growth

Management Skills for Supervisors and Team Leaders

Process Optimisation — From Mapping to Takt

Coaching for Manufacturing Managers

Topics: Lean (4) · Quality (4) · Costs (4) · Management (4) · Digitalisation (1)

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