🧭 Context
At Lapp, Lean isn’t just a buzzword—it’s an industrial way of life.
Every day, production teams work directly on the shop floor, spotting deviations, suggesting improvements, and launching projects. But before Kostango, these efforts were scattered across files, spreadsheets, and emails—making collaboration and visibility difficult.
The challenge: centralize everything without adding bureaucracy, empower teams without slowing them down, and provide clear visibility without drowning in KPIs.
❗Challenges
Continuous improvement is a core principle at Lapp, but over time, the process had become overly complex:
- Dispersed tools, hard to sync
- Limited visibility on ongoing improvement projects
- Lean rituals perceived as burdensome due to lack of proper tools
- Difficult to sustain long-term engagement
- Operators were not fully involved
What was missing was a common platform—a clear, visual cockpit to orchestrate all improvement levers, from the shop floor to the executive committee.
🛠️ Solution
Kostango was implemented as a digital performance cockpit with a simple goal: put action at the center.
Immediate impact:
💡 Smooth deviation reporting
- Operators now report anomalies easily via tablet or smartphone: Gemba walks, 5S audits, safety checks
- 500+ deviations logged in the first year
- Each deviation automatically routed to the right department: Quality, HSE, Maintenance
📌 Centralized action tracking
- All actions from the floor are consolidated, prioritized, and monitored until closure
- 1,100+ active actions in the platform
- Closure rate above 70%
- Action plans updated in real-time by the teams themselves
🚀 Structured improvement projects
- Each Lean initiative has a clear management framework
- 117 projects tracked simultaneously
- Average of 18 actions per project
- Methods adapted to each case: A3, QRQC, 8D
📊 Digitalized shop floor rituals
- Shift reports and SQCDP points are animated through visual templates
- 50 reports filled daily for over 3 years
- Daily priorities tracked live with the teams
- A visual, engaging culture embraced across all levels
