Worldclass in production

When it comes to productivity improvement, figuring out what needs to be done is only part of the equation. The challenge is turning it into reality. Our customized production systems help you achieve sustainable productivity gains. And the improvements are there to be seen in the impact on EBIT.

Production

We analyze and think strategically, but don’t stop there. Implementation is all. That means mobilizing and training your employees, and providing an environment for fast, concentrated and accurate work. The result is an integrated, holistic solution for your value stream, with the dividend showing in real money terms.

Production

We accelerate production processes across all stages of production.

Production

We minimize set-up times for product changes.

Production

We combine speed and quality, ensuring low costs.

Production

Our integrated approach to optimization reduces working capital.

Production strategy and footprint

Finding the right level of vertical integration and selecting suitable locations – the long-term success of your company depends on these decisions. Our more than 30 years of experience in strategy and implementation will help you find the right answers. Together with you, we develop a groundbreaking production strategy. Thus, your company can adapt its value-added depth and (global) footprint to dynamic influencing factors and achieve a higher resilience. ConMoto offers you well-established solutions for the following issues:

  • Production structures and technology portfolio
  • Core competences and make-or-buy
  • Securing company sites by performance improvement
  • Plant dimensioning and consolidation within the value creation network
  • Relocation of production
  • Expansion of production capacity at existing sites
  • Redesign of production and logistics systems

Especially in the event of a sudden drop in demand, it is necessary to quickly and agilely assess the impact of the current downturn on the overall capacity of the production network. If there is a threat of persistent overcapacity, companies must act decisively and consistently. This includes make-or-buy decisions and insourcing options such as reintegration. Consequently, it is essential to use existing capacities and protect the value chain from supplier failures.

Manufacturing and logistics footprint

The revision of the footprint should be based on market demand. The clear principles are:

  • Assume the perspective of the market and your customers
  • Compare locations using relevant key figures (KPIs) and include optimizations in your calculations
  • Understand scale effects and the impact of complexity
  • Degree of automation: consider differences between manual and automated processes
  • Include total costs and liquidity, e.g. due to longer supply chains
  • Consider your management system and indirect areas (right-sizing)
  • Use scenarios to develop concrete options for the value creation system

The results of numerous projects testify to the success of our approach for a sustainable production footprint. Based on market demand and considering your current capacities, the ConMoto consultants will work with you to achieve overall improvements in a four-stage process:

1 Initial assessment

As part of our initial assessment, we determine the individual (global) footprint of your company and define relevant requirements based on markets, customers and existing strategies.

2 Ideal footprint

Strategic positioning forms the basis for deriving the ideal footprint for a greenfield situation or approach.

3 Evaluation and decision template

Based on the ideal footprint, we derive the options to best achieve your goals. In doing so, we consider all current limitations, agilely evaluate different scenarios and provide a resilient decision template.

4 Business and implementation plan

We develop a business plan with work packages, responsibilities and a clear schedule. This includes concrete implementation plans for each site with a transparent calculation of cost effectiveness as well as detailed investment and plant structure planning.

Production systems that increase your performance

A well-organized and efficient production process depends on systematic improvement. Ad hoc measures might result in one-off productivity gains, but they generally remain isolated improvements.

A first-class production system is possible only if an overarching system is in place. If there is one key issue, that is it. We can optimize your entire value stream with a goal-oriented analysis of your plant and an integrated calculation of potential output.

We plan and design lean production systems, drawing on the latest scientific research, to improve the overall effectiveness of your business.

We deploy tried-and-tested methods such as value stream mapping and design and the ConMoto basic enhancement process, and follow these up by engaging with shop floor management. Manufacturing costs can decrease by 14 to 18 percent and overall equipment effectiveness (O.E.E.) can see increases of 14 to 22 percent, depending on the type of production.

Industry 4.0 is a reality and the automation and digitalization of manufacturing is accelerating all the time. That is why we include networking of product and manufacturing plants as well as transport and storage systems in our down-to-earth cost-benefit analysis.

Together, we can achieve breakthrough change. Our job is to help you deliver better results, quicker than ever before.

Staying ahead of the competition with automation

Technological innovation and new production processes such as the Internet of Things (IoT), 3D printing and integrated assembly solutions are changing the production philosophy of many industries. Those who cannot keep pace will turn out to be among the losers. Because automation starts at the “hot spots” of production systems: producing quickly and error-free – and thus efficiently and flexibly. ConMoto has decades of experience in the planning and implementation of automation processes and solutions (Design4Automation):

  • Turn-key factory automation, turn-key solutions for production and logistics
  • Low-cost automation
  • Modularization of the plant structure
  • Standardization and intelligent linking of hardware and software components, manufacturing execution software
  • Engineering of digital twins, configurators for plant components and subsystems
  • Object-related 3D simulation, product and process FMEA
  • Integrated process monitoring
  • Design of human-machine interfaces (HMI)
  • Use of human-robot collaboration (Cobots)

The perfect automation solution for measurable success

You benefit from ConMoto’s methodological knowledge as well as the industry and project experience of our consultants. The decision in favor of automation must be guided by market requirements and economic considerations. We create a business case that takes all economic and technological aspects into account during the feasibility test.

Our assessment is based on a transparent total cost of ownership and lifecycle analysis. ConMoto finds the right automation solution for your company within the scope of a clearly structured process:

1 Identification of key processes

Analysis of production processes and staff deployment for the current product, analysis of product requirements

2 Determination of the degree of automation in process workshops

Determination of automation steps, analysis of technical product limits, creation of a suitable cycle time model

3 Business case

Rough planning of possible variations, preparation of the line concept and the feasibility study; systematic limitation of variations

4 Automation concept

Definition of decision-making criteria, decision matrix and automation content

5 Implementation planning

Final digital validation, preparation of specifications, start of supplier selection

6 Implementation

Implementation plan, Run@Rate production capacity test, serial acceptance, rollout in more than one site

The advantages of our jointly developed automation solutions speak for themselves:

  • Shortened engineering process and reduced commissioning period
  • Increase in O.E.E. and output
  • Reduction of total lead times and cycle times
  • Flexible setup concepts
  • Improved logistics routine with integrated material supply including reduced layout and line space
  • Reduction of direct personnel costs

The success of our projects, documented performance enhancements and improved resource efficiency can be measured in reduced manufacturing costs of up to 30 percent.