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Reengineering assembly logistics for automotive production site
Category: Consulting
Process: Production
Introduction
As a result of structural and organizational changes, the supply of material in assembly in an east German factory belonging to a major OEM could no longer run efficiently or cover its costs.
In order not to put current production at risk and to set the plant up to be flexible for the future, IndustrieHansa was appointed to optimize the overall supply process and highlight and implement areas with potential for reducing the use of resources.
Solution: Overall optimization of logistics processes and the use of resources in the provision of materials and the flow of materials and information based on a process analysis.
Puncture points
Benefits
The "Reengineering assembly logistics" project delivered a capacity saving of 20% compared with the former levels of staffing. Measures were also drawn up for a further 10% potential reduction in resources. Alongside these quantitative results, the entire assembly supply area was optimized in terms of transparency, standardization, flow and reliable supplies. The groundwork was also laid for continuing with the improvement system (CIP) implemented in the project. This will allow the customer to be able to respond flexibly to future changes while retaining a high level of quality.
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As a result of structural and organizational changes, the supply of material in assembly in an east German factory belonging to a major OEM could no longer run efficiently or cover its costs.
In order not to put current production at risk and to set the plant up to be flexible for the future, IndustrieHansa was appointed to optimize the overall supply process and highlight and implement areas with potential for reducing the use of resources.
Solution: Overall optimization of logistics processes and the use of resources in the provision of materials and the flow of materials and information based on a process analysis.
Puncture points
- Recording of supply processes in assembly
- Establishment of potential for reducing the resources needed
- Analysis of processes into value-adding and non-value-adding activities
- Reorganization of work content and job descriptions
- Implementation of binding standards (work schedules, info boards, fault reports etc.)
- Optimization of supply (visualization, kanban)
- Planning routing
- Implementation of a CIP system
Benefits
The "Reengineering assembly logistics" project delivered a capacity saving of 20% compared with the former levels of staffing. Measures were also drawn up for a further 10% potential reduction in resources. Alongside these quantitative results, the entire assembly supply area was optimized in terms of transparency, standardization, flow and reliable supplies. The groundwork was also laid for continuing with the improvement system (CIP) implemented in the project. This will allow the customer to be able to respond flexibly to future changes while retaining a high level of quality.
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