Production Optimisation

Cost and time savings with outstanding product quality

Any organisation that competes in the global market feels the pressure on production costs almost daily. As your partner, therefore, we often undertake cost reduction projects. Costs can be optimised both in relation to the product itself and in production. We support you here in all phases of production and planning: this begins in the design phase, because that is where 70 to 80% of the product manufacturing costs are already defined.

Using a best practice cost calculation, we determine the optimum price of all the parts of a product. We work with you to jointly develop the perfect manufacturing concept. In doing so we draw on the longstanding expertise of our engineers from product development, production engineering and implementation. Our experts identify the cost drivers in the manufacturing process and develop solutions that make you competitive in the long term. The integration of product and production plays a decisive role here.

Advantages for the customer

  • We show you the savings potential in your production and how much you can save.

  • In many cases, costs can be reduced by using modern technology.

  • Diverse savings can be achieved through the interplay between product parts and their properties as well as in production.

  • Cost optimisation does not compromise the quality of your products. Indeed, this is often improved.

  • We examine production as a whole and include all relevant influences and parameters in the cost optimisation process.

  • By increasing effectiveness, we lower your product costs and find solutions that make your production sustainably competitive.

When it comes to production optimisation, the focus is on the entire process and not just the products. Taking an integrated view, we analyse for you whether the arrangement of the production steps is optimum, identify cost drivers, evaluate the production technology used and determine where it pays to use modern technology. We also offer process and method consulting, including extensive simulation options.

As we have been planning and manufacturing plant for decades, the combined knowledge of our engineers, who know exactly what works in the long term and what does not, is brought to bear here.

Production optimisation – the big picture

System-based calculation – flexible calculation thanks to extensive database

When calculating production costs, we rely on experience that is always available in the form of databases and knowledge-based calculation tools. These include:

  • Material databases
  • Machine hourly rates
  • Labour cost tables
  • Process and production times
  • Cost data for logistics and packaging
  • Overhead tables
  • Part prices
  • Tooling costs

The integrated system allows calculations to be made during the development phase as well as target price calculations including cost reduction potential.

Best practice cost calculation – what the product must cost in production

What can and should a product cost in production? Using a complete bottom-up calculation, we calculate the optimum part price of an existing product thanks to our many years of expertise and our in-house specialists. These include:

  • Plastic parts: injection-moulded, compression-moulded, blow-moulded, extrusion, press-moulded, foam, composite parts
  • Electronic components: cable rods, electronic modules, lighting, printed circuit boards
  • Metal parts: die cast, sintered, sand cast, precision cast, sheet metal, bending, extrusion, stamping and turning parts

The result shows where the greatest potential for cost reduction can be found in the production process.

Process optimisation – choose the right optimisation methods

Since the environment is constantly changing, an optimum system can only be achieved temporarily. Therefore, systems must be regularly scrutinised with regard to continuous optimisation. In process optimisation, it is important not to just pull a standard solution out of the hat and adapt it to resolve all problems "across-the-board". Processes must always be considered in their individual context. If this is done and we keep the standard in mind when optimising, very efficient processes can be developed. We use the following process optimisation methods:

  • Kaizen, lean production and lean management
  • Value stream analysis and value stream design
  • Sensitivity analysis - critical parameter analysis
  • Methods-Time-Measurement (MTM)
  • SMED - Productivity increase through reduction in setup time


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