Initial situation:
- High scrap rates, inefficient shift changes, and underutilized injection machinery were causing performance and cost issues.
- No systematic process for continuous improvement or standardized work instructions in place.
- Critical need for cost reduction and productivity gains across multiple product lines.
Our approach:
- Implemented over 250 targeted actions, from scrap reduction to optimized shift change procedures.
- Introduced “first good piece” methodology, reducing machine and material waste.
- Reorganized toolroom operations and upgraded mould tooling concepts for better maintenance and quality.
- Deployed training programs and 5S standards on the shopfloor to improve process discipline.
- Installed structured daily production reviews and escalation routines to monitor performance.
Results:
- €330k+ annual savings achieved through direct measures, including €98k from shift optimizations and €79k from labor efficiency.
- Scrap costs reduced significantly, cutting deburring expenses by 50%.
- Operator productivity improved by >30% through dual-machine operation models.
- Sustainable process improvements and skill-building embedded in daily operations.
Conclusion:
Targeted efficiency offensive – sustainable cost reductions and significant increases in productivity realised in day-to-day production.
