Client situation
The client manufactures luxury vehicles with an already established Lean Production System and high variant spread. However, the company was facing several challenges like problems during ramp-up of the second series to production line, introduction of a third series on the same assembly line and volume increase doubled within a few months
Approach
EFESO supported the automotive Client by:
- Taking a structured & parallel approach for Lean Transformation with early manager involvement including:
- 3-week analysis and concept phases
- 6-week implementation phase
- 8-week light support phase
- Ensuring there was focus on KPIs per division right from the start
- Hours Per Unit (HPU), Right First Time (RFT), Defects Per Vehicle (DPV)
- Recording comprehensive video of process sequences and joint waste analysis for 2 series model variants
- Improving process and design of new series in the form of 3P (Pre-Production-Planning)-light workshops
- Consolidating Yamazumi boards of all processes and parallel line balancing of the three series
Overall, a targeted implementation with prioritization of metrics.
Results
- 85% increase in manufacturing volumes of finished cars at the plant
- 15-25% productivity increase after only 8 weeks
- 20% Total Productivity at the plant confirmed after 5 months
- 30% improvement of Quality KPI "Right First Time" (RTF)
- -30% reduction in the assembly line cycle
- Reduction of rework effort through quality control loop improvement
- Focused Lean Transformation along the entire assembly line with 5 parallel projects
- Smooth introduction of pre-series vehicles into production
