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A manufacturer of safety vehicles had to combine numerous third-party and in-house components into a consistent overall system. All components had to meet the high requirements of the safety classification. However, final assembly did not take place at the main plant, but at an external assembly plant, which made coordination, quality assurance and speed of response particularly challenging.
The small series production involved a wide variety of materials, component geometries and safety-relevant individual components. Reworking and assembly required in-depth specialist knowledge, as any deviation could jeopardize certification. Quality errors had to be corrected immediately in order to avoid production stoppages, delays and cost-intensive replacement deliveries.
An experienced Zettl specialist underwent several months of intensive training in the specific requirements of safety vehicle assembly. He then took over the complete reworking, small parts assembly and testing of all relevant assemblies on site. All work steps were backed up by image documentation, error reports and daily feedback to the main plant so that deviations could be identified and rectified immediately. The progress of series production remained stable at all times.
All safety-related audits were passed without any deviations. Production interruptions due to quality problems were completely avoided. Around 92% of all rejected components could be returned to the production process through immediate reworking on site - a significant cost reduction due to the elimination of replacement deliveries and stable series releases.
92 % of rejects successfully reworked and reused
Production stops due to quality defects completely avoided
380,000 euro cost reduction thanks to elimination of spare parts and stable processes
