Manufacturing Companies
Here, you'll discover a collection of in-depth case studies showcasing how RTW has successfully partnered with manufacturing companies to drive improvement, innovation, and growth. Each case study highlights specific challenges faced by these companies, the tailored solutions provided by RTW, and the measurable results achieved. Explore these stories to gain insights into how RTW can help your company reach its goals.
The Challenge
A Medium Seize Automotive Part Supply Company – Leading its Sector - With demand growing during the last 2 years the capacity of the plants got to its limits. The deployment of new software to optimize operations throw-out the pilot plant and its constant optimization through man-machine interfaces and analysis of gathered data.
The Solution
It provided a maturity and materiality analysis of the operations in order to propose opportunituies of optimizations in a IND 4.0 Roadmap format with steps and solutions to be incorporated. The plan also made reference to the technology options and implementation plan. The program was managed with dashboards updating its data constantly.
Used WorkSpace: OPEX IND 4.0
Results
The outcome was understanding best practices in adjusting the tooling and optimizing the set-up times and even forecasting issues of future production batches. The solution was scaled to several plants with similar polymer transformation processes. Capacity increase was measured as + 32%
The Challenge
A Large Seize Generic Pharmaceutical Company – Local and International Player - With demand growing and diversifying product categories during the last years managing capacity and productivity through different production cells and final packaging lines were a challenge. Optimizing patches and set up times as well as controlling maintenance interventions were key to increase OEE.
The Solution
A detailed assessment on the RTW platform followed by recommendations on quick fixes as well as lean optimizations were a phase 1, followed by an analysis of simple but powerful ROI solutions with IOT data collection technology linked to first MES production monitoring system. The MES system was also integrated to a preventive maintenance system to schedule maintenance activities.
Used WorkSpace: OPEX IND 4.0
Results
The outcome impacted OEE in 4% as well as more flexibility in production rescheduling and with the possibility to offer to customer a better OTIF. Also, maintenance cost optimization in the sense of MRO expenses was perceived.
The Challenge
A Medium Gear Box Manufacturing Company – Very Strong Engeneering - With Strong competitive move from other suppliers and most importantly from international producers the engineering and manufacturing company had to rethink the production costs and most importantly optimize the use and the direct costs of its manufacturing facility.
The Solution
It provided an assessment to understand the direct manufacturing costs as well as the utilization of milling and gear grinding equipment. The design of a Lean and IND 4.0 Roadmap helped to focus the initiatives to optimize machine availability as well as the direct cost of ever asset. Data acquisition from PLCs and CNCs helped to have a online Dashboard to optimize operational efficiency.
Used WorkSpace: OPEX IND 4.0
Results
The outcome of the program was a reduction of direct cost including financial expenses alocated by equipment as well the possibility to optimize OEE by some percentage points. It also gave the company the possibility to avoid additional investments to increase production capacity.
The Challenge
A Large Seize Automotive Assemby Company – Several Plants - With the opportunity to optimize its assembly line in order to produce a larger product spectrum as well as increase flexibility of its production line the automotive company embarked in a analysis of the IND 4.0 potential, business case and final road map of implementation. It was developed for one pilot plant and later deployed to other production facilities.
The Solution
RethinkingWorks provided a team of high-level experts with deep understanding in automotive and in the Fourth Generation Industrial Revolution. The team used the platform for assessments and training of the project team and in the second phase of the program mentoring support was delivered with tools and templates to design the IND 4.0 Road map and the final business case for implementation
Used WorkSpace: OPEX IND 4.0
Results
The Roadmap was delivered with a very positive ROI. It was so positive that the company decided to deploy it to other factories immediately as well as develop phases of further IND 4.0 maturity for its strategic plan. One important outcome was also the understanding that many of the existing OPEX programs were sometimes conflicting and were been developed in duplication. Rationalization was an important benefit.