PRODUCT AND PRODUCTION OPTIMIZATION –
COST AND TIME SAVINGS AT THE HIGHEST PRODUCT QUALITY

Whoever is in (global) competition feels the cost pressure of production on an almost daily basis. As a partner to our clients, we therefore often take on projects aimed at cost reduction. Costs can be optimized both for the product itself as well as within the manufacturing process. We support our clients in all production and planning stages. Nowadays, this already begins in the design phase, because 70 to 80% of the product manufacturing costs are already allocated here.

Using a best-practice cost calculation, we can determine the best price for all parts of the product. To do this, we develop the optimum manufacturing concept together with our clients. Here we draw on the many years of expertise of our engineers from product development, production engineering and implementation. Our experts find the cost drivers in the manufacturing process and develop solutions to ensure your long-term competitiveness. The networking of product and production plays a decisive role here.

EDAG PS Produktkostenmanagement

BENEFITS
FOR CLIENTS:

  • TRANSPARENT ANALYSIS:

    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.

  • GUARANTEED QUALITY:

    Cost optimization does not affect the quality of your products. In fact, it will often be improved.

  • HOLISTIC APPROACH:

    We examine the manufacturing process as a whole and involve all relevant production factors in the cost optimization.

  • SUSTAINABLE COMPETITIVENESS:

    We reduce your product costs through increased efficiency and find solutions that make your production sustainable and competitive.

Optimierung

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

Zahnrad auf Zeichnung

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.

This includes:

  • Material databases

  • Machine-hour rates

  • Wage costs tables

  • Process and production times

  • Cost data for logistics and packaging

  • Overhead cost tables

  • Part prices

  • Tool costs

This holistic system enables both development-related calculations, as well as target price calculations with cost-reduction potential to be run.

Fertigungsteile

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.

This includes:

  • 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.

Zeichen

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

STILL HAVE
QUESTIONS?

Dirk Gittner

PLEASE CONTACT
DIRK GRITTNER
HEAD OF FACTORY PLANNING
E-MAIL: DIRK.GRITTNER@EDAG-PS.COM