White text on a light gray background reads UMS+ in large letters, with AN EXPLEO COMPANY in smaller text below.

Improvement of assembly processes through optimized development in the automotive industry

Initial situation

  • A European car manufacturer needed support in ramping up newly installed assembly lines to ensure stable production quickly
  • The market environment was highly competitive and characterized by high quality requirements and tight delivery deadlines
  • The newly developed product family was technologically challenging in terms of the manufacturing processes selected, which led to high scrap costs and additional work
  • In order to stabilize production, significant increases in quality, performance and availability should be brought about

Achievements

0
Rework reduced
1,8 million €
Savings realized over the project duration
0
Committee costs reduced

Our approach

  • Provide methodical support to sprint teams in the following areas
    • Carry out a holistic analysis of the current situation using Six Sigma methodology and identify the causes of rejects (individual parts, measuring systems, machines, process steps)
    • Support the creation of Digital Twin for the entire production process in order to quantify the greatest benefit contribution
    • Derive and implement technical solutions
    • Introduce measures to prevent errors (Poka Yoke)
  • Involve employees closely to ensure acceptance of the measures

Further cases

Automotive

In-line defect detection through the introduction of AI-supported inspection systems in the automotive industry

Automotive

Increasing the accuracy of quality inspections through artificial intelligence in the automotive industry

Automotive

Increased efficiency in quality inspections through AI-supported image recognition in the automotive industry

All cases

Discover more references.