Practical example

Optimizing flow production at an agricultural machinery manufacturer

We optimized the flow production of complex, highly varied products for a leading agricultural machinery manufacturer. Our goal was to sustainably increase the first-pass yield and manufacturing quality, as well as to improve the supply situation on the production line.

Background

The customer operates a flow-line production system for highly complex products in various configurations, with a batch size of one. Challenges included missing parts, supply bottlenecks, and an above-average amount of rework.

Specific task

Our task was to analyze the existing data from ERP and MES systems in order to create transparency and identify patterns in error profiles. We conducted detailed root-cause analyses and developed optimization measures based on lean production principles.

KBC's Approach

We applied established quality methods such as fault tree analysis, Ishikawa diagrams, and the 5 Whys analysis. Problem-solving teams were formed, and we provided support for the implementation of sustainable solutions. By creating transparency regarding the situation with missing parts and supply, we were able to achieve targeted improvements.

A man, bald, with blue eyes and glasses, smiling, wearing a white shirt and a dark blue suit, standing with both hands in his pants pockets

Martin Betz

Director

Impact achieved

Thanks to the measures we implemented, we were able to sustainably increase the first-pass yield and product quality. The supply and missing-part situation on the production line was significantly improved. Quality issues and the defect rate per manufactured product were demonstrably reduced. We established a smooth-running production line and ensured that the workload on employees was reduced. The first-pass yield was increased by over 40%.