LEAN CHAMPIONS

Participants & Projects

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Kostal Bulgaria Automotive Ltd.

2025

Goal: Increase line productivity and efficiency by balancing assembly stations.

Main result: Productivity rose from 15.6 to 17.4 units per labour-hour (+10%).

Goal: Reduce rejected modules at the illumination calibration station on the VW MEB G2 line.

Main result: The number of defective modules decreased.

Goal: Reduce the cost of storing additional packaging in an external warehouse.

Main result: Storage costs fell by €345,401.

Goal: Automate internal logistics with AGV/AIV transport and Milk-Run routes serving Halls 1–5.

Main result: PFEP and Milk-Run calculations for Halls 1–5 were completed to support investment decisions.