The client for this mandate was a global manufacturer of automotive components headquartered in Germany. The relative cost position of the German factories was no longer competitive in an international comparison and traditional efficiency improvement programs promised little potential. With the application of smart factory technologies, great potential for increasing performance was identified: Among other things, an increase in the number of units produced of 50 to 95 percent, a reduction in internal error costs of 40 to 60 percent. The project objective was to quantify the value potential, design a solution architecture and develop a comprehensive release plan, taking into account technological and change aspects, and to begin the transformation.
From identifying the value potential to the step-by-step Smart Factory transformation
With his experience, acquired in many Smart Factory projects, the interim manager was able to realize the project together with the management and the project team.
As core technologies, the interim manager introduced vertical and horizontal integration, real-time interfaces to machines and systems, dynamic scheduling, intelligent workpieces and a digital assistance system for machine operators.
The detailed and quantitative analysis of the value potential and the implementation planning in technological and transformative stages with value potential per stage proved to be particularly effective. In each implementation step, the planned realization of potential and the planned value-creating solution components gave all organizational areas involved the necessary direction.
