We show you the savings potential in your production, and how you can economize.
STATE-OF-THE-ART MANUFACTURING TECHNOLOGY:
In many cases costs can be reduced by using modern technology.
INTERLOCKING PRODUCT AND PRODUCTION:
The interplay of product parts, their properties and their production can achieve various savings.
Cost optimization does not affect the quality of your products. In fact, it will often be improved.
We examine the manufacturing process as a whole and involve all relevant production factors in the cost optimization.
We reduce your product costs through increased efficiency and find solutions that make your production sustainable and competitive.
PRODUCTION OPTIMIZATION – THE BIG PICTURE
The whole process is in focus during production optimization (and not just the products). Adopting a holistic view, we analyze for the clients whether or not the production steps are optimally arranged, identify cost drivers, assess the manufacturing technology used, and determine where it pays to use modern technology. As we have been both planning and manufacturing production plants for 40 years, the accumulated knowledge of our engineers flows into this – because they know exactly what works and what does not work in the long term.
Our clients can always rely on these benefits:
Since 2004 we have been supporting industrial customers in the optimization of their production in a wide range of varied projects
Our own know-how in the areas of production engineering, product development, plant engineering
Our own knowledge database with machine hours, labor costs, material costs and process costs
Process and method consultancy including comprehensive simulation capabilities and design of a digital twin
Our own planning and implementation experts with more than 9000 man-years of engineering experience
CALCULATING WITH SYSTEM – FLEXIBLE CALCULATION THANKS TO AN EXTENSIVE DATABASE
For the calculation of manufacturing costs, we rely on experience that can be called up at any time from databases and knowledge-based calculation tools.
Wage costs tables
Process and production times
Cost data for logistics and packaging
Overhead cost tables
This holistic system enables both development-related calculations, as well as target price calculations with cost-reduction potential to be run.
BEST PRACTICE COST CALCULATION – WHAT THE PRODUCT MUST COST DURING PRODUCTION
What can and should a product cost to produce? Using a complete bottom-up calculation, we calculate the optimum part price of an existing product, based on our many years of experience and using our in-house specialists.
Plastic parts: Parts from injection molding, transfer molding, blow molding, extrusion parts, die parts, foam parts and composite parts
Electronics: Wiring harnesses, electronics modules, lighting, circuit boards
Metal parts: Pressure cast, sintered, sand cast and fine cast parts; sheet metal parts, flexible parts, extruded parts and stamped and turned parts
From the result we can determine where the greatest potential for cost reductions are to be found within the production process.
PROCESS OPTIMIZATION – CORRECTLY SELECTING METHODS FOR OPTIMIZATION
A system must always be self-scrutinizing and self-optimizing, because the environment permanently changes. In the optimization process, it is important to us not just to draw on standard, off-the-shelf solutions and adapt them “to all problems”. Processes must also always be viewed within their individual context. If this succeeds, and if you have the standard “in mind” during optimization, very efficient processes can be developed.
We apply the following methods for process optimization:
Kaizen Lean production and lean Management
Value stream analysis and value stream design
Sensitivity analysis – critical parameter analysis
Methods-time measurement (MTM)
SMED – increase in productivity by reducing setup time