Top performance in the foundry
Requirement
By integrating these proactive production strategies, we ensure smooth operation, minimize downtime, optimize plant performance, reduce operating costs and create a safe working environment. This contributes to the long-term efficiency, productivity and competitiveness of our company.
Solution
By reducing the number of employees by 2 while maintaining the same level of quality, we have found a solution to reduce costs.
Nevertheless, we are able to achieve higher productivity by working more efficiently.
Rescheduling employees’ break times has led to an optimized use of working time.
In addition, we have trained production employees as forklift drivers to avoid bottlenecks in the event of breakdowns and ensure smooth operations.
These measures help to reduce costs and increase efficiency.
Result
The measures we implemented enabled us to achieve savings of 22.22%.
At the same time, we were able to increase the output quantity from 480 parts per shift to 700 parts, which corresponds to an improvement of 45%.
The production machine is now able to produce 480 minutes per shift instead of 450 minutes per shift.
Another advantage is that the employees can transport their parts themselves and no additional driver is required.
This saves us money.
We also have the flexibility to transfer an employee from production to logistics in the event of forklift breakdowns to ensure that operations run smoothly.
These optimizations have not only increased efficiency, but also reduced costs.
Outlook
Since the successful changeover, the new system has been continuously implemented and is running smoothly.
The measures implemented to reduce costs and increase efficiency have proven their worth and are showing sustainable results.
Through regular reviews and adjustments, we always stay up to date in order to identify and implement further potential for improvement.
Our aim is to maintain an optimal operating structure and efficient workflow in the long term in order to offer our customers the best possible service.
Our customer is a leading specialist in the field of iron casting, producing high-quality castings for the automotive industry, among other things.
With modern technologies and advanced processes, we offer this customer tailor-made solutions.
Our dedicated team works closely with our customer to meet individual requirements and achieve first-class results.
