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In the course of a series production start-up, an automotive supplier was faced with strongly fluctuating quantities and internal capacity bottlenecks. In particular, the pre-assembly of certain interior components could no longer be fully covered in-house, which jeopardized the timely delivery of the series production line.
A solution was required that would create additional assembly capacity at short notice and at the same time guarantee the highest quality standards. The implementation had to take place parallel to series production, with simultaneous just-in-time delivery to the customer's assembly line and flexible scalability in the event of fluctuating call-off quantities.
Our team took over the pre-assembly of the interior components in a specially equipped three-shift operation. Thanks to clearly defined processes, continuous quality checks and coordinated logistics, the parts were delivered to the customer on time and in the exact quantities required. Close coordination with the customer's series planners ensured that production peaks were absorbed and bottlenecks were completely avoided. Billing was transparent and based on unit costs, a flexible model that remained economical even with changing batch sizes.
The external pre-assembly relieved the customer's production lines and ensured series supply despite capacity fluctuations. Thanks to three-shift operation and just-in-time delivery, the series ramp-up was completed without delays. The successful project established itself as a permanent model for additional assembly capacities, scalable, quality-assured and economically efficient.
Series ramp-up without delays and 100% on schedule
Cost savings of 18% thanks to outsourced assembly
Durable, economical solution with flexible scalability
