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Production optimisation mechanical engineering
Case Studies
Production optimisation mechanical engineering
Expert:
Dipl.-Ing. Nico Pohlmann
Task
Significant reduction in the reject rate of drive shafts at the start of production (SOP) in three-shift operation (reject rate was between 60 -70%)
Industry/ Function
Automotive supplier
Interim Project Manager
Plant for drive shafts
Implementation
Recording of all operations on all machines and their critical characteristics at each stage of production
Recording and evaluation of non-conforming processes by “running along” in production
Measurement and evaluation of the causes of failure as NiO part
Implementation of developed corrective measures in the processes
Re-organisation of sub-processes and the process organisation
Implementation of process-stabilising measures on individual operations by adapting the production process (hot forging, soft and hard turning)
Changing a turning process into a drilling process
Ishigawa workshops conducted
Result
Scrap rate reduced from > 65% to approx. 15% after three months to SOP
Customer reference
Factory of a well-known automotive supplier for complex drive shafts
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Dipl.-Ing. Nico Pohlmann
Senior Partner
+49 40 8000 845 92
pohlmann@fup-ag.com
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