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Analysis and optimization of the economic viability of the level of automation in engine assembly
Category: Consulting
Process: Production
Introduction
A high level of automation does not necessarily result in efficient work at optimum cost. With this fact in mind, the managers at an Austrian plant belonging to an international OEM decided to analyze the economic viability of engine assembly automation.
A team from IndustrieHansa with experience in this field was tasked with this analysis and their stated objective was to gain findings which could be used for subsequent process optimization.
Solution: Analysis of the influence of various levels of automation, assembly concepts and production/quality standards on the overall economic viability of engine production.
Puncture points
Benefits
The alternative assembly concept (low-cost automation) developed by IndustrieHansa on the basis of the results of the analysis resulted in investment savings of €7.4 million. Despite having to increase the workforce by 10 members of staff, economic viability was greatly improved. By training staff it was also possible to significantly improve assembly quality and as a result greatly reduce rework (>15%). Coupled with a willingness to take on more responsibility, these factors increased efficiency by 10 percent.
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A high level of automation does not necessarily result in efficient work at optimum cost. With this fact in mind, the managers at an Austrian plant belonging to an international OEM decided to analyze the economic viability of engine assembly automation.
A team from IndustrieHansa with experience in this field was tasked with this analysis and their stated objective was to gain findings which could be used for subsequent process optimization.
Solution: Analysis of the influence of various levels of automation, assembly concepts and production/quality standards on the overall economic viability of engine production.
Puncture points
- Survey and analysis of the actual status
- Design concept and production of various strategies with different levels of automation and production/quality standards
- Development of an alternative assembly concept under consideration of low-cost automation
Benefits
The alternative assembly concept (low-cost automation) developed by IndustrieHansa on the basis of the results of the analysis resulted in investment savings of €7.4 million. Despite having to increase the workforce by 10 members of staff, economic viability was greatly improved. By training staff it was also possible to significantly improve assembly quality and as a result greatly reduce rework (>15%). Coupled with a willingness to take on more responsibility, these factors increased efficiency by 10 percent.
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