Kohler GmbH
Neckarsulm based, Kohler GmbH is a leading expert in C-parts management, fastening technology, and intelligent logistics solutions. As a reliable partner for industry and trade, the optimization of procurement and logistics processes is at the core of the company’s philosophy. To strengthen its competitive advantage and create even greater value for customers, the company embarked on a journey to digitize its proven Kanban system. The introduction of a powerful e-Kanban solution marked a key milestone in advancing Kohler’s vision of smarter, more connected logistics.
Established Pull Processes as a Foundation
One of the key reasons behind the success of Kohler’s digital transformation was that the company didn’t have to start from zero. Long before the introduction of the IKS system, Kohler had already relied on a manual, card-based Kanban system—a setup deeply rooted in the principles of pull control and lean management.
Building on this strong foundation, the company made a strategic decision to evolve and optimize its processes. The goal was clear: to take a proven system and bring it into the digital age. By doing so, Kohler aimed to boost efficiency, enhance transparency, and secure a sustainable competitive edge in an increasingly dynamic market.
The search was on for a solution that not only met modern requirements but could also be seamlessly integrated into existing workflows—supporting both operational continuity and innovation.
“The challenge for Kohler was not to introduce a completely new way of thinking and an unfamiliar process model within the company, but rather to elevate an already established and functioning process to the next level”
reports Mr. Thomas Barbara, Head of Supply Chain Management.
Strategic Imperative for Digitization
After careful evaluation, Kohler chose for the IKS e-Kanban system from manufactus.
“There were two main reasons behind our decision: the software is incredibly easy to use, and the costs are very reasonable. This combination made IKS the ideal solution for Kohler’s needs.” explains Mrs. Barbara
The implementation process is still ongoing, allowing for an agile, step-by-step rollout across the organization. This approach ensures that each phase can be tested, refined, and aligned with the company’s operational realities—creating lasting value at every stage.
The following table contrasts the limitations of the manual Kanban system with the benefits of a digital solution like IKS, clearly illustrating how digitalization directly supports Kohler’s strategic goals of greater efficiency, transparency, and competitiveness.
Manual Kanban (Initial Situation) |
IKS e-Kanban (Solution) |
|
Signal Transmission |
Slow; physical transport of the Kanban card | Real-time; immediate digital transmission via barcode scan |
Process Transparency |
Low; local and time-delayed | High; global and immediate visualization of the complete Kanban situation |
Analysis Capability |
Manual; complex, periodic | Automated; with a mouse click, in real-time |
Error Susceptibility |
Medium; manual input errors | Low; high process reliability through clear digital identification |
Scalability |
Limited; high administrative effort per new control loop | High; easy connection of new customers or suppliers via web portals |
Customer Integration |
Low; customer is a passive recipient | High; proactive involvement of the customer and full transparency regarding supply |
Key Success Factors in Implementation
From practical experience, one factor emerged as particularly critical for a successful implementation: employee training and documentation.
“It became clear that a simple and easy-to-understand guide for using the system is essential. This ensures that all employees – even those covering for colleagues on vacation or sick leave – can operate the system confidently and without errors”
noted Mrs. Stoltenfeldt, Assistant Central Sales Services.
The clarity and accessibility of instructions thus proved to be a key driver of user acceptance and smooth system operation, forming a cornerstone of Kohler’s E-Kanban success.
Qualitative Successes in Daily Operations
Today, IKS supports the pull processes between Kohler’s central warehouse and various customers supplied via the Kanban principle (customer Kanban). While implementation for additional customers is still underway, the positive effects of IKS in the digital transition are already clearly visible.
Kohler has identified several significant benefits of IKS in daily operations that directly enhance customer satisfaction:
- Faster Kanban Order Processing: Digital workflows accelerate the entire ordering process.
- Increased Transparency: Customers gain improved traceability and visibility of their orders.
- Efficient Analytics: The system enables quicker, easier analysis of Kanban processes, supporting more informed decisions and continuous process optimization.
Goals and Perspectives
Kohler GmbH has a clear vision for the future of its E-Kanban system. The key objectives are:
- Transitioning all Kanban customers to the IKS system from manufactus to fully leverage its benefits.
- Finalizing system integration through dedicated interfaces to further enhance automation and streamline operations.
With the introduction of the IKS E-Kanban system, Kohler has taken a major step toward digitalization and process optimization. The initial results are highly promising and provide a solid foundation for further system expansion.
“Digitalizing our Kanban processes with IKS is an important step in increasing our efficiency and providing even better service to our customers,” concludes Mr. Barbara.
Kohler serves as an excellent example of how a company can strategically implement the IKS E-Kanban system to optimize operational workflows and position itself for a future-ready, competitive edge.