- Mechanical engineering
Securing supplies after an investor has joined the supplier
Particularly in the case of unclear combinations of responsibilities, even at the shareholder level of manufacturing companies, it becomes obvious right down to the production processes that unclear responsibility structures cause errors and inefficiencies. Especially in international compositions of different roles of know-how carriers, industry experts and investors, differences of interest often arise that cause the current production process to deviate from the optimum.
In the project example, we were active in analyzing a critical supply situation in component production and initiating improvement measures under high time pressure. In close cooperation with the customer, requirements were coordinated and translated into feasible production packages. At the plant itself, it became obvious that there were organizational grievances and confusion of responsibilities, since in addition to the established workforce, the investor also brought “his own specialists” into the operational organization. Rarely did the saying “too many cooks spoil the broth” fit as well as it did here. We have identified various ways to equalize responsibility and ensure stability in the executive areas. We accompanied the jointly favored path with all participations until full implementation on site.
Profile
Company size
Location
Germany
Period
1.5 years
Branch
- Mechanical engineering
Percentage of individual services
Challenge
Supply not guaranteed in 18-shift operation
OEE core processes: Pressing 62%, Milling 58%, Bonding 44%.
Change rate of critical derivative in customer's plant from SOP: 39%.
Lack of personnel qualification and capacity
Inadequate logistics subcontractor management
Procedure
Control dates for the implementation of a key figure-based control of production
Reduction of downtimes and scrap by means of PDCA cycle
Reduction of process times by sequence optimization of automation
Test series for quality improvement along the entire process chain
Fixing of framework agreements at Tier 2 level
Development of system for safety, reorder points and escalation processes
Results
Securing supply in 15-shift operation
OEE increase of core processes to: Pressing 67%, Milling 73%, Gluing 67%.
Reduction of cycle times in adhesive bonding per derivative by: 16% / 12% / 8%.
Change rate of critical derivative at customer plant: 1%
Establishment of complexity-variable safety and reorder points
Daily supply report including performance-based forecast curve
The project in detail
Project Highlights
Significant increase in organizational process availability
Creation of transparency and clarification of responsibilities
Management of the customer - supplier interface
