- Automotive, Mechanical engineering
Production areas typically operate at the edge of their capabilities. In terms of an orientation towards efficiency and investment protection, “scraping the limit” is therefore actually the ideal operating point – but the system then immediately collapses in on itself if there is an impact from outside that suddenly stops the production capability.
This case references a fire at a foundry that was operating at full capacity supplying various industries, including mass-produced vehicle manufacturers. We were called directly to the scene of the incident in order to find solutions at extremely short notice. In parallel, we identified, consolidated and evaluated a wide variety of conceivable scenarios, leaving out no solution, no matter how far-fetched it might seem. In addition to the development of recommendations for the best alternative solution in the scenario at hand, we also accompanied the implementation up to the post-processing for all insurance processes (incl. damage assessment due to loss of production, bridging costs and repair work).
Profile
Company size
Location
Germany
Period
6 months
Branch
- Automotive, Mechanical engineering
Percentage of individual services
- reactive situation stabilization
- holistic concept development
- risk analysis production performance
- Reaktive Situationsstabilisierung
- Ganzheitliche Konzepterstellung
- Risikoanalyse Produktionsperformance
Challenge
- Short-term loss of production capacity due to the fire at a magnesium die-casting cell at the German customer site
- Due to the previous relocation of the die-casting tool from the USA to Germany - also fire-induced - the supply situation is tense
- The requirements of the American customer location can currently only be met by air freight.
Procedure
- Convening a 24-hour task force for the short- term repair of the die-casting tool
- Creation of capacities in a further die-casting facility by means of order redeployment and shift extensions
- Counterpart for insurance and surveyors and control of internal capacities to enable the new casting shop and preservation of neighboring halls
- Consolidation of all fire-induced costs
Results
- After the customer's initial estimate of theamount of damage of approx. € 9.5 million, all fire-related costs of € 14.2 million were covered by the insurance company
- 5 days after the fire event, series production was started at the replacement plant
- Vehicle production was not affected
- After 6 weeks, supply was switched from air to sea freight
The project in detail
Project Highlights
High confidence in our holistic recommendations
Interlocking of logistical, technological and economic aspects
Management of a complete series interruption
