Participants & Projects

Increasing line productivity through stable flow

Goal: Improve line productivity through layout changes, controlled buffers, workload balancing and standardized work.

Main result: Output per operator increased by more than 15%.

Q2 2026 – Improvement Project

Goal: Increase MTU assembly line productivity by improving wave soldering utilization and process quality.

Main result: Wave soldering productivity reached 87% for the leading product.

Q3 2026 – Improvement Project

Goal: Improve wave soldering parameters and First Pass Yield (FPY) for MTU assemblies.

Main result: First Pass Yield (FPY) improved significantly across four key products.

Reducing changeover time

Goal: Reduce casting changeover time from 6 h 15 min to 3 h by improving boron nitride cleaning in Q1.

Main result: Changeover time fell from 6 h 15 min to 2 h 15 min, an improvement of approximately 64%.

Q2 2026 – Improvement Project

Goal: Reduce casting changeover time through fewer internal operations and better external preparation.

Main result: Changeover time fell from 6 h 39 min to 2 h 27 min, an improvement of 63%.

Q3 2026 – Improvement Project

Goal: Create a shared system of current packaging instructions to reduce repacking incidents by 90% by September 30, 2026.

Main result: A shared packaging instruction management system was implemented.

Optimizing delivery lead time

Goal: Eliminate delays in outsourced component polishing and deliver orders on time.

Main result: Processing cost fell from approximately €5,120 to €2,650–2,720 per batch; lead time fell from 32–65 days to 2 weeks.

Q2 2026 – Improvement Project

Goal: Reduce material issuing time from the Bravo warehouse through better flow and warehouse organization.

Main result: Material issuing time fell from 7 h 24 min to 4 h 50 min, exceeding the target.

Q3 2026 – Improvement Project

Goal: Reduce repeated work by connecting KERN counting scales to a shared database and electronic reporting.

Main result: Repeated reference preparation time fell from approximately 23 s to zero when a suitable reference was available.

Increasing production capacity

Goal: Increase casting capacity by at least 20% through better space use and 5S in Casting and Plastification.

Main result: Capacity increased by at least 25%.

Q2 2026 – Improvement Project

Goal: Implement Autonomous Maintenance Steps 1–3 in Plastification and 5S in Turning to improve equipment reliability.

Main result: The Autonomous Maintenance plan reached 18.2%, exceeding the 11% target.

Q3 2026 – Improvement Project

Goal: Improve bushing flow and inventory through standard storage, FIFO, Kanban and Min/Max stock levels.

Main result: On-Time Delivery (OTD) rose from 97% to 98%, reaching the target.

Reducing production batch changeover time

Goal: Reduce batch changeover time on the first machine group of line C through standardization and workplace organization.

Main result: Batch changeover time fell by 62%; the 5S score rose from 52 to 80 points.

Q2 2026 – Improvement Project

Goal: Reduce batch changeover time in Preparation Department B through better cleaning, reloading and adjustment.

Main result: Batch changeover time fell from 41 min 55 s to 23 min 17 s, an improvement of 45%.

Q3 2026 – Improvement Project

Goal: Reduce batch changeover time on the third machine group in Preparation Workshop B.

Main result: Batch changeover time fell from 26 min 31 s to 17 min 49 s, a reduction of 33%.

Introducing Autonomous Maintenance

Goal: Introduce Autonomous Maintenance on the 200 t injection moulding machine and complete 5% of the annual plan in Q1.

Main result: Autonomous Maintenance was introduced on the 200 t machine; 5% of the annual plan was completed in Q1.

Q2 2026 – Improvement Project

Goal: Implement 5S and Autonomous Maintenance in KOBU II Injection Moulding to improve machine care.

Main result: Autonomous Maintenance plan completion rose from 5% to 20%; the 5S score rose from 25 to 60 points.

Q3 2026 – Improvement Project

Goal: Use Value Stream Mapping (VSM) to improve material and logistics flow for DAI MMA – SHROUDS.

Main result: Major sources of losses were identified and a stronger alternative packaging solution was developed.

Increasing warehouse capacity

Goal: Increase capacity within the existing warehouse area and reduce picking time per line from 330 s to 300 s.

Main result: Average picking time per line fell from 330 s to 264 s.

Q2 2026 – Improvement Project

Goal: Increase OEE through faster decisions, traceable actions and consistent use of Lean tools in a digital environment.

Main result: Daily operational meetings were digitalized through the iObeya platform.

Q3 2026 – Improvement Project

Goal: Increase monthly output from 790 to at least 1,000 units by eliminating production and material flow bottlenecks.

Main result: Average monthly output rose from 790 to approximately 1,245 units (+57.6%).

Reducing overall scrap

Goal: Reduce overall scrap in the core-making area from 27% in 2025 to 22% by the end of Q1 2026.

Main result: Overall scrap fell from 27% to 26% in Q1 2026; digital scrap registration and analysis were introduced.

Q2 2026 – Improvement Project

Goal: Reduce overall core-making scrap through better defect visibility, registration and analysis.

Main result: Overall scrap fell to 20% in Q2 2026, reaching the target.

Q3 2026 – Improvement Project

Goal: Reduce core-making scrap from 27% in 2025 to 18% in Q3 2026, towards the annual target of 15%.

Main result: Overall scrap fell from 27% to 18%, reaching the Q3 2026 target.

Increasing productivity

Goal: Increase Q1 productivity by 20% in wood preparation through continuous flow, layout improvements and less movement and waiting.

Q2 2026 – Improvement Project

Goal: Improve polyurethane foam deliveries and warehouse organization with 5S and a Pull System.

Main result: A Pull System was introduced and material flow reorganized; the 5S level rose from 18% to 87%.

Q3 2026 – Improvement Project

Goal: Increase Frame Assembly Workshop efficiency from 80% to at least 90% through better workplaces, flow and ergonomics.

Main result: Average production efficiency rose from 80% to 93%, exceeding the 90% target.

Quality control and Autonomous Maintenance

Goal: Introduce quality control and Autonomous Maintenance for Category B and C machines, targeting 40.7% of the annual plan in Q1 2026.

Main result: Process control, KPI visualization and 5S/Autonomous Maintenance audits were introduced; 90% of the set objectives were achieved.

Q2 2026 – Improvement Project

Goal: Improve quality through in-process control, operator responsibility and 5S/Autonomous Maintenance audits.

Main result: The annual plan reached 81% completion against an 87% target, or 93.1% target achievement.

Q3 2026 – Improvement Project

Goal: Improve Wood Assembly Workshop organization through 5S, standardization and structured audits.

Main result: The 5S audit score rose from 17.5% to 92.5%, exceeding the 90% target.

Increasing productivity

Goal: Increase Q1 output per operator by 10%, from 10.5 to 11.5, through stable flow and line balancing.

Main result: Output rose from 10.5 to 12.5 units per operator, an improvement of approximately 19%.

Q2 2026 – Improvement Project

Goal: Increase Exopulse weekly productivity from 35 to at least 70 units through management, standards and balanced flow.

Main result: Weekly productivity rose to 80 units; First Pass Yield reached 91% and the 5S score rose from 39% to 73%.

Q3 2026 – Improvement Project

Goal: Replace isolated Deburring workstations with a stable production flow balanced to takt time.

Main result: Operator productivity rose from 99 to 136 units per day (+37%).

Optimizing AC motor refurbishment costs

Goal: Improve diagnosis and repair so motors are rewound only when necessary, reducing the rewinding share from 45% to 25%.

Main result: Quarterly savings were €27,241; planned annual savings were €81,637.

Q2 2026 – Improvement Project

Goal: Reduce internal findings in refurbished DC motors from 60% to 25% through sustainable quality control.

Main result: Internal findings fell from 60% to 24.24%; the 5S target was achieved at 92.5%.

Q3 2026 – Improvement Project

Goal: Increase machine storage capacity by at least 30%, halve retrieval time and save €5,000 annually.

Main result: Machine storage capacity rose from 80 to more than 124 machines (+55%).

Increasing roasting process efficiency

Goal: Reach 68% efficiency in coffee roasting and grinding in Q1, towards the annual 2026 target of 73%.

Main result: Work progressed towards the 68% Q1 efficiency target and established the improvement plan towards 73% GE.

Q2 2026 – Improvement Project

Goal: Increase coffee roasting and grinding efficiency (GE) by eliminating production losses and increasing capacity.

Main result: Overall efficiency (GE) rose from 66% to 70.1%, reaching the target.

Q3 2026 – Improvement Project

Goal: Reduce coffee roasting losses to 11.00% or less while maintaining product colour and moisture requirements.

Main result: Average roasting losses fell from 11.14% to 10.97%, reaching the Q3 target.