Efficiency Increase in Assembly at a Manufacturer of Metal Components – Process Optimization for Efficient Processes
The project focus of Bjelic & Barth was on optimizing production processes in order to bring about an increase in efficiency in the organization and control.
Sources of waste and inefficiencies were to be minimized – the focus was specifically on the areas of picking and final assembly in order to identify productive and unproductive times. Further focus areas were material provision and logistics.
The result of the project was a clear identification of the processes to be optimized. The results should show optimization possibilities in the processes and present suggestions for increasing productivity.
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We transform unused potential into efficient processes and sustainable performance improvement.
Prof. Dr. Alkesandar Bjelić
- Result of the consulting project:
- Decentralized production and assembly spread over several halls instead of centrally in the main hall
- Centralization of production to improve processes and reduce walking distances
- Material flow is not linear, which leads to long transport routes and unnecessary intermediate storage/stations. The official intermediate warehouse therefore has many empty spaces
- Maximum shortening of transport routes through route changes and optimized utilization of the intermediate warehouse
- Employees sometimes have a high proportion of unproductive time
- Increasing motivation through the introduction and adaptation of processes and procedures. By involving the employees, they were able to re-identify with their employer and their work and drove the implementation of the measures forward with a great deal of personal responsibility
- Productive employees perform both low- and high-value activities
- Strengths-weaknesses analysis per person in order to use the employees adequately and analogously to their qualification
- Devices are not used optimally or are not available.
- Concept for better utilization or acquisition of strategically necessary equipment
- Pre-assembly lacks the necessary space. As a result, the arrangement of the devices and tools is suboptimal
- Thanks to the new area concept, pre-assembly can now be carried out with optimal space
- Two old CNC milling machines (> 15 years) pose a high risk of failure due to their age
- Purchase of a new milling machine and retention of the old machine, which had a low failure time
- Another CNC milling machine is not used optimally because parts are sometimes processed manually.
- Training of the co-workers to make ideal use of the milling machine
Analysis results and measures:
Thanks to the systematic process optimization by Bjelic & Barth, annual savings of EUR 600,000 – 800,000 can be achieved.
