Automotive and suppliers
Automotive expertise with decades of experience
Our managing directors, many partners, project managers and consultants at ConMoto have decades of experience in the automotive industry. OEMs and suppliers in this key industry face the challenge of managing the COVID-19 demand shock and problems in their supplier networks. At the same time, the industry is amid structural change. Car manufacturers and their supplier must invest billions in a sustainable product portfolio. They must develop alternative driving technologies and software instead of hardware. Now, the pandemic acts as a catalyst for the transformation of the industry. Margins will remain under severe pressure, consolidation – and thus, the distinction between winners and losers – will accelerate.
High productivity, profitability for manufacturers and suppliers
The ConMoto projects show that the key to solving these problems lies primarily in increasing productivity, resulting from the restructuring and transformation of production systems and therefore, increasing profitability. Our activities ensure cost flexibility and cost reduction. They aim at sustainable cost leadership. We help our automotive clients to build an organization that performs exceptionally in production, logistics and all indirect areas. The goal is to strategically reposition your company. We answer questions about the correct production footprint and offer strategic/operational levers regarding the rightsizing and consolidation for your facility network. In addition, we work with our clients on future-oriented product developments and, ultimately, profitable business models. Are you ready to enjoy sustainable market success and become a trailblazer as a provider of individual mobility?
OEM and suppliers: an industry sector is in worldwide transition. With strategic competence and implementation strength, we secure a strong competitive position for our clients. The results of more than 1,000 successful projects speak for themselves.
A new design for the production line
DAutomation is one of the most relevant levers for reducing the costs per unit and improving the efficiency of production sites. One of ConMoto’s projects with a leading German automotive supplier provides a good example. The initial question was: Moving the staff-consuming pre-production and assembly of components for e-cars abroad or making the German site more productive by implementing a new automation strategy? At the end of a three-month project period, the decision fell in favor of automation.
Business case automation
In order to establish a business case, we analyzed the whole production process with a distinct focus on staff and machine cycles. The design of the automized target process included a new machine layout. Assessing the machine modules, the project team was able to calculate the necessary investment costs of as much as six million euros at a net present value of 30 million euros.
A fully devised line layout served as the base for discussions of the detailed design with mechanical engineers. They confirmed the layout’s feasibility and even remained slightly beneath the projected investment costs of six million euros with their target prices. The automated production line cost only approx. 1.7 million euros more than the previously mostly manually operated line whilst producing significantly higher quantities. The investment per unit even decreased by more than 20 percent and the automized line outperforms manual production significantly.
A selection of project results:
- Doubling the output by increasing the overall equipment effectiveness from 80 to more than 91 percent and cycle time reduction by 38 percent
- Reduction of own staff by 67 percent
- Reduction of the costs per unit by 14 percent
Our client profits from significant competitive advantages regarding the predicted market growth in the e-cars sector due to efficiency raises and significantly reduced production costs.
An automotive supplier company produced an ever-increasing variety of products in a fatctory that has grown for the last 50 years. Today, these specific premises have an annual turnover of 370 million euros and 1,400 employees. They inhabit a partially very sophisticated manufacturing and process technology. This led to a situation of several years without meeting the target results. Different initiatives for continuous improvement (CIP measures) were also insufficient to close the gap. Therefore, ConMoto was commissioned to plan and implement a sustainable cost-cutting program.
Initially, the project team put all influenceable costs to the test. Production, logistics, inventory and work-in-progress, maintenance as well as product contribution margins and material costs were analyzed. Based on the detected waste and a comparison with best practices, ambitious but feasible potentials were identified – especially for direct and indirect personnel, as well as in inventory, material and maintenance costs.
IDuring the six-month implementation phase, five project teams redesigned the individual production areas along the entire value chain according to lean principles and developed levers to reduce inventory costs. The alignment of capacities to requirements, process optimization and the comprehensive introduction of tugger trains significantly increased the effectiveness and efficiency of logistics. The tugger trains also enabled a forklift-free production, which also improved qualitative factors such as occupational safety.
Due to the optimization of processes and organization as well as the introduction of TPM (Total Productive Maintenance), maintenance was reframed, and the availability of capacity-critical systems in particular was a considerably enhanced. Applying the linear performance pricing method contributed to a significant reduction in material costs.
Savings goals exceeded
The target values defined in the potential analysis could even be exceeded: total savings of 13.75 million euros, which equals 3.7 percent of the turnover, where achieved. With this effective project, the ConMoto consultants also laid the foundation for a successful cooperation with the client, sustained for years now. The project results
- Reduction of personnel costs (direct and indirect) by 15%
- Reduction of logistics costs (except staff) by 23%
- Stock reduction by 50%
- Savings regarding the examined material costs of 6%
STUDIES & DOWNLOADS
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