Securing supplies of technically challenging structural body components

The pressure to innovate when it comes to products that appear technically ambitious is a key driving force behind securing or expanding market shares. All too often, however, concepts are defined that pose extreme challenges to the series production of components, both in terms of output and quality. Together with our partners in the project, we always seek a quickly realizable optimum from these variables.

One project example from our assignments dealt with extremely complex tooling concepts for the series production of complex structural car 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 everyone 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 clear improvement in the jointly processed production areas.


Company size


Czech republic


9 months


Percentage of individual services

reactive situation stabilization
holistic concept development
risk analysis production performance


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


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


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

Organizational measures to increase motivation

Similar projects

We look forward
to hearing from you.


roeren GmbH

Ludwig Erhard St. 13a
84034 Landshut

+49 871 966448-07