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Here are highlighted some examples from of our projects:
- The initial situation of the client at the time of our intervention;
- The problems we direct our attention to and our best efforts;
- Activities that, in direct and continuous collaboration with the client, we put in place, to approach the encountered problems;
- The overall benefits obtained from the project, often well above the objectives set at the kick-off of our activities.
[+ details]Case 1 - Chocolate Plants (Product Development and Process)
Client situation
- Market leader in equipment for the production of chocolate, part of an international group.
- A site with about 200 employees and support staff from the holding
- Producing a custom order
Important addressed issues
- Product competitiveness
- High cost and complexity of the product
- Onerous after-sales activities
- Design by contract
Task
- Functional Analysis of the plant and definition of the new development line
- Modular development of the plant, based on individual stand alone machines, and simultaneous reduction of the component varieties
- New aesthetic impact
Benefits
- Product cost reduced by 15%
- Clutter reduced by 20%
- Increase overall performance
- Facilitation of cleaning operations in the new plant
- Increase community index (up to 100% in the most important machine)
- Reduction by 40% of the time to market orders
- Two patents for the most important production machine
[+ details]Case 2 - Automatic Warehouse (Product Development and Lean process)
Client situation
- Market leader in automated warehouses, part of a national group of equipment manufacturers.
- A site with approximately 300 employees and support staff from the holding company (1,200 employees)
- Producing a custom order
- Strong vocation for technological innovation
Important issues addressed
- Competitiveness of the product
- Cost Containment
- Containment of the delivery time and installation at the customer
- Onerous after-sales activities
- Design by contract
Task
- Lean process (prior to installation by the customer) and product development from transfers component as an goal area
- Virtual modular development of the plant
- Implementation of the new modular design software
Benefits (regarding the transfers)
- Product cost reduced by 21%
- Cost of the contract (included in the product), reduced by 36%
- Development orders - time reduced by 41%
- Reduction of codes by 53%
- Reduction of inventory by 67%
[+ details]Case 3 - Boilers for Domestic Use (Product Development)
Client situation
- Market leader in boilers for domestic use.
- Approximately 600 employees
Important issues addressed
- Product competitiveness (performance and costs)
- Launching a new product range
- Occupational diseases in assembly
Task
- Definition of the new range
- Modular development and reduction of the various components
- New aesthetic impact
Benefits
- Product cost reduced by 4.54%
- Line workspace reduced by 23%
- Reduction of codes by 38.9% c
- 35.6% less errors
[+ details]Case 4 - Automotive (Product Development)
Client situation
- Multinational Company
- Opportunity to be the first supplier to offer a type of innovative product on the car market
- Innovation Process blocked on chronic quality problems
Important issues addressed
- Defects in achieving the functions of a module of the product
- Incapacity to meet customer specifications
Task
- Functional Analysis of the module
- Physical model of the product functionality
- Development of 6 alternative concepts. Selecting the best alternative
- Development of test equipment
- Support for the construction, test and validation of the chosen option
Benefits
- Adoption of a new product concept, able to meet customer specifications
- Test and validation within the tolerance limits
- Understanding the interactions between the various modules of the product
[+ details]Case 5 - Automotive (Product Development - Process)
Client Situation
- Multinational Company
- Opportunity to be the first supplier to offer a type of innovative product on the car market
- Innovation Process blocked due to chronic quality problems
Important issues addressed
- High number of scraps in the prototyping
- Incapacity to reach the target cost
- Volume production is not sufficient to meet customer requirements
Task
- Quality Functional Deployment of the product, analysis of variances and critical correlations
- Physical model of the defects of the product
- Statistical Process Control on critical parameters.
- Design of Experiments on critical parameters, resulting in changing one of the materials used
Benefits
- Waste reduced by 11 times (equivalent to saving several million €)
- Identify feasible tolerances of individual components
- Upgrading of product specifications and process
[+ details]Case 6 - Automotive (Product and Process Development, Internal and Suppliers)
Client situation
- Multinational Company
- Opportunity to be the first supplier to offer a type of innovative product on the car market
- The Innovation Process required excellent suppliers to develop new manufacturing processes with high performances
Important issues addressed
- High risk investments
- Incapacity to meet the cost of the target transformation
- high level waste
- Installed capacity too low
Task
- Integration of the stages of processes development in the stages of product development
- Selection of suppliers based on criteria of the total cost of the product along the total life cycle
- Suppliers integration and co-design of the assembling and testing technology
Benefits
- Respect the milestone of “Production Start”
- Savings on investment of about 15%
[+ details]Case 7 - Transforming Product Development Processes
Client situation
- Architecture of Product Platform was made without re-organizing the product development process
- Poor communication between the various R & D locations
- Difficult integration of suppliers
- Mission and Vision are not homogeneous among different people
Important issues addressed
- Incapacity to reach the target cost
- Incapacity to reach the targeted Time To Market
- Incapacity to reach the total target cost of the project
Task
- Value Stream Mapping
- Lean Development assessment
- "Reflections" on key business processes
- Implementation of the Design Review system
- Process Implementation for the Cost Management
- Revision of the Organization
- Development of system indicators for R & D
- Revision of the Project management process
Benefits
- Respect for milestone “Production Start”
- Savings on investment of about 15%
