+30%
Productivity increase through cycle time reduction
Bottleneck Cycle Time Reduction Boosts Productivity by 30%
A leading global manufacturer of automotive components partnered with EFESO to address a production bottleneck within its new electric vehicle battery cooling systems line. Through a data-driven, cross-functional approach, EFESO helped the client reduce cycle time, boost productivity by 30%, and set the foundation for a potential 60% volume increase with minor product design modifications.
Automotive and Commercial Vehicles
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Our Client
The client is a multinational manufacturer of automotive components, recognized for its technical expertise and strong industrial footprint. The company recently expanded its portfolio with a new business line dedicated to electric vehicle battery cooling systems, rapidly gaining significant market share in this emerging segment.
“We can postpone investments for 2 years coping with the demand in the meanwhile.
“
The Challenge
The client’s new product line for the electric vehicle market faced a severe production bottleneck at the press stage.
Despite numerous attempts to improve performance, the issue persisted due to:
- Process not in basic conditions: Established “habits” were treated as fixed rules, resulting in unnecessary steps and extended cycle time.
- Incomplete understanding of failure modes: Root causes were only partially identified, preventing sustainable improvements.
- Limited link between product and process design: Potential design adjustments that could enable higher productivity were not explored.
Real Results Achieved Together
The collaboration delivered measurable performance gains and created a solid foundation for further scalability.
+60%
Potential volume increase pending customer approval of minor product design modifications
Transformation Impact
- Eliminated inefficiencies and optimized bottleneck performance.
- Strengthened cross-functional collaboration between R&D, Quality, Maintenance, and Production.
- Established experimental methodologies that generated new process knowledge.
- Built readiness for substantial volume growth with minimal design changes.
Our Approach
EFESO’s approach combined rigorous technical analysis with strong cross-functional collaboration:
- Correlating Product and Process
• Linked product design characteristics to process performance.
• Identified unnecessary phases that increased cycle time. - Restoring Basic Process Conditions
• Conducted in-depth analysis of process parameters and variability.
• Re-established process standards and eliminated inefficiencies. - Cross-Functional Problem Solving
• Facilitated hands-on collaboration between R&D, Quality, Maintenance, and Production teams.
• Designed and executed targeted experiments to generate factual knowledge and validate improvement hypotheses.
Related Services
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Ready to Unlock Hidden Capacity in Your Production Line?
- Eliminate bottlenecks and boost productivity without major capital investment
- Stop accepting “that’s how we’ve always done it” as the reason for underperformance
- Join manufacturers who’ve transformed constraints into competitive advantages
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