- Automotive
The pressure to innovate with technically ambitious products is a key driver for securing or expanding market share. All too often, however, concepts are defined that pose extreme challenges to volume production of components, both in terms of output and quality. Together with our partners in the project, we always look for a quickly realizable optimum from these variables.
One project example from our assignments dealt with extremely elaborately designed mold concepts for the series production of complex structural body components. Due to problematic tool structures, it was difficult to identify the respective causes for losses in quality and output in an environment that was unclear due to many part numbers. Both organizational and technical aspects led to a loss of process reproducibility. Together with all parties involved, we were able to implement a clear solution strategy and successive improvements. Today, the plant is an established part of an international supply chain and shows a significant improvement in the jointly processed production areas.
Profile
Company size
Location
Czech republic
Period
9 months
Branch
- Automotive
Percentage of individual services
- reactive situation stabilization
- holistic concept development
- risk analysis production performance
- Reaktive Situationsstabilisierung
- Ganzheitliche Konzepterstellung
- Risikoanalyse Produktionsperformance
Challenge
- Production standstill at customer's plant
- Production peak in 2 months cannot be handled in 21 shift model
- Ø 28 customer complaints per month
- Ø 376 ppm per month
- Scrap costs of approx. 123,000€ per month in the press shop
- OEE core processes: Press shop 55%, body shop: 65%
- Inadequate structure and process organization
Procedure
- Capacity analysis of press shop and body shop
- Relocation of approx. 20% of press tools
- Use of external toolmaking capacities
- OEE improvement program for body shop and press shop
- Implementation of an optimization project for series and new tools
- Optimization of the organizational structure and implementation of a recruiting process for managers and operational employees
Results
- Ensured that customer call-offs are served in a 15-shift model
- Ø 3 customer complaints per month
- Ø 46 ppm per month
- Reduction of scrap costs in the press shop by 60% to approx. 50,000€ per month
- OEE core processes: Press shop 65%, body shop: 84%
- Complete processing of tooling issues by internal tool shop
- Reduction of tool-related malfunctions by Ø 5%
The project in detail
Project Highlights
Innovative products with modern manufacturing strategies
Complex tool structures in the press shop
Increase in availability of plant technology
