Project Example

Optimization of Flow Production at an Agricultural Machinery Manufacturer

For a leading agricultural machinery manufacturer, we optimized the flow production of complex products with high variance. Our goal was to sustainably increase the first-pass yield and manufacturing quality, as well as improve the supply situation on the production line.

Background

The client operates a flow production for very complex products in various versions with a batch size of 1. Challenges included missing parts, supply bottlenecks, and above-average rework efforts.

Specific Task

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

KBC Solution Approach

We applied established quality methods such as fault tree analysis, Ishikawa diagram, and 5-Why analysis. Problem-solving teams were formed, and the implementation of sustainable solutions was supported. By creating transparency regarding the missing parts and supply situation, we were able to effect targeted improvements.

Männliche Person, keine Haare, blaue Augen mit Brille, lächelnd, trägt ein weißes Hemd und dunkelblauen Anzug, stehend mit beiden Händen in den Hosentaschen

Martin Betz

Director

Achieved Effect

Through our measures, we were able to sustainably increase the first-pass yield and product quality. The supply and missing parts situation on the production line was significantly improved. Quality problems and error frequency per manufactured product were demonstrably reduced. We established “calm on the production line” and ensured relief for employees. The first-pass yield was increased by over 40%.