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Automotive produktion reengineering to implement lean manufacturing processes
Category: Consulting
Process: Production
Introduction
Because of the way that structures had evolved over time and organization changes, an automotive manufacturer from southern Germany was producing identical vehicles in different ways at three locations. Resolving this unsatisfactory situation and sufficiently optimizing the production processes within assembly at the individual locations lay at the heart of a reengineering project which the manufacturer planned to undertake with external assistance.
IndustrieHansa experts were tasked with assisting the customer in this work.
Solution: Laying the groundwork for the same production processes in all factories by synchronizing the core processes and equipment, using identical installation sequences and supply concepts wherever possible and identical containers and packaging.
Puncture points
Benefits
Process stability was greatly improved on the assembly lines. The new supply concept also dramatically reduced the need for staging areas. Alongside these quantitative results, the whole supply area become more transparent. Using the same production systems for all three factories ensures a high level of transparency and allows improvements to be introduced in the factories much faster.
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Because of the way that structures had evolved over time and organization changes, an automotive manufacturer from southern Germany was producing identical vehicles in different ways at three locations. Resolving this unsatisfactory situation and sufficiently optimizing the production processes within assembly at the individual locations lay at the heart of a reengineering project which the manufacturer planned to undertake with external assistance.
IndustrieHansa experts were tasked with assisting the customer in this work.
Solution: Laying the groundwork for the same production processes in all factories by synchronizing the core processes and equipment, using identical installation sequences and supply concepts wherever possible and identical containers and packaging.
Puncture points
- Overall optimization of production processes in assembly
- Recording and evaluation of core processes in assembly
- Establishment of potential for reducing the resources needed
- Analysis of processes into value-adding and non-value-adding activities
- Producing a synchronization model for the reference plant and assembly plants
- Ensuring the same supply concepts and containers / packaging wherever possible
Benefits
Process stability was greatly improved on the assembly lines. The new supply concept also dramatically reduced the need for staging areas. Alongside these quantitative results, the whole supply area become more transparent. Using the same production systems for all three factories ensures a high level of transparency and allows improvements to be introduced in the factories much faster.
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