Q1 2025 – Completed Improvement Project
Goal: Increase yield for 6082 alloy profiles by optimizing final cutting length.
Main result: Yield increased from 58% towards the 65.8% target.
LEAN CHAMPIONS
Participants & Projects
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Alcomet AD
2025Q1 · 2025
Q1 2025 – Completed Improvement Project
Goal: Improve profile and parts supply to the Automotive Shop through planning and coordination.
Main result: The number of pallets fell from 182 to 98, a reduction of 46.15%.
Q2 · 2025
Q2 2025 – Completed Improvement Project
Goal: Introduce Autonomous Maintenance, 5S and visual standards around the 25 MN press.
Main result: Cleaning and inspection standards were introduced.
Q2 2025 – Completed Improvement Project
Goal: Introduce Autonomous Maintenance on the HELLER H2000 CNC machine to improve condition and reduce downtime.
Main result: The machine’s basic condition improved.
Q3 · 2025
Q3 2025 – Completed Improvement Project
Goal: Expand Autonomous Maintenance to the stretcher, final saw and rollers of the 25 MN press.
Main result: Handling-related scrap decreased; the data is still stabilizing.
Q3 2025 – Completed Improvement Project
Goal: Expand Autonomous Maintenance to Heller 1 and Heller 2 after its successful implementation on Heller 3.
Main result: The 5S audit score rose from 25 to 90 points.
Q4 · 2025
Q4 2025 – Completed Improvement Project
Goal: Introduce Autonomous Maintenance Steps 1–3 and 5S in more areas of the 25 MN press.
Main result: Handling-related scrap on the 25 MN press decreased.
Q4 2025 – Completed Improvement Project
Goal: Introduce Autonomous Maintenance Steps 1–3 and 5S on the Chiron DZ15W CNC machine.
Main result: The CNC machine’s basic condition improved significantly.
APS Trading Ltd.
2025Q1 · 2025
Q1 2025 – Completed Improvement Project
Goal: Reduce production time per module by 30%.
Main result: The number of operators was reduced by 39%.
Q2 · 2025
Q2 2025 – Completed Improvement Project
Goal: Reduce material preparation time and optimize packaging.
Main result: Material issuing time fell by 70.2%.
Q3 · 2025
Q3 2025 – Completed Improvement Project
Goal: Consolidate TPH processes and improve logistics and layout to reduce cycle time from 37.5 s to 30 s per unit.
Main result: Cycle time fell from 37.5 s to 26.7 s per unit, an improvement of 28.8%.
Q4 · 2025
Q4 2025 – Completed Improvement Project
Goal: Sustain the year’s improvements through stable standards, better workplaces and daily Lean practices.
Main result: Results from previous quarters were stabilized and sustained.
Kostal Bulgaria Automotive Ltd.
2025Q1 · 2025
Q1 2025 – Completed Improvement Project
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%).
Q2 · 2025
Q2 2025 – Completed Improvement Project
Goal: Reduce rejected modules at the illumination calibration station on the VW MEB G2 line.
Main result: The number of defective modules decreased.
Q3 · 2025
Q3 2025 – Completed Improvement Project
Goal: Reduce the cost of storing additional packaging in an external warehouse.
Main result: Storage costs fell by €345,401.
Q4 · 2025
Q4 2025 – Completed Improvement Project
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.
LEM Bulgaria Ltd.
2025Q1 · 2025
Q1 2025 – Completed Improvement Project
Goal: Increase equipment availability through Autonomous Maintenance.
Main result: Equipment availability increased by more than 3%; 20% of the 2025 Autonomous Maintenance plan was completed.
Q2 · 2025
Q2 2025 – Partially Completed Project
Goal: Implement the annual Autonomous Maintenance plan and improve 5S in the maintenance workshop.
Main result: The team did not attend the Q2 meeting; the results will be presented at the Q3 meeting.
Q3 · 2025
Q3 2025 – Completed Improvement Project
Goal: Implement Autonomous Maintenance Steps 1–3 around the HC5FW line.
Main result: The 5S audit score rose from 88 to 95 points.
Q4 · 2025
Q4 2025 – Completed Improvement Project
Goal: Improve the LFxx10 layout through 5S and Kaizen to free 95 m² and prepare for new product transfers in 2025–2026.
Main result: Approximately 95 m² of production space was freed up.
Linamar Light Metals Ruse Ltd.
2025Q1 · 2025
Q1 2025 – Completed Improvement Project
Goal: Restore Autonomous Maintenance and improve the efficiency of the FA7 core-making machine.
Main result: Machine abnormalities were resolved; the 5S score rose from 68 to 85 points.
Q2 · 2025
Q2 2025 – Completed Improvement Project
Goal: Restore Autonomous Maintenance and improve the efficiency of the FA4 core-making machine.
Main result: Efficiency and workplace organization improved; the 5S score rose from 70 to 88 points.
Q3 · 2025
Q3 2025 – Completed Improvement Project
Goal: Improve efficiency and stability in the core-making area at Linamar Light Metals Ruse Ltd..
Main result: The 5S score rose from 72 to 82 points.
Q4 · 2025
Q4 2025 – Completed Improvement Project
Goal: Improve core-making efficiency through better resource control and a stable production process.
Main result: Q4 efficiency rose from 41% to 55%, reaching the 55% target.
NIKI Ltd.
2025Q1 · 2025
Q1 2025 – Completed Improvement Project
Goal: Implement Autonomous Maintenance and 5S for Category A machines in the Blanks area.
Main result: Equipment efficiency improved; the 5S audit score rose from 23 to 68 points.
Q2 · 2025
Q2 2025 – Completed Improvement Project
Goal: Implement Autonomous Maintenance and 5S for Category A machines in the Blanks area.
Main result: Equipment efficiency improved.
Q3 · 2025
Q3 2025 – Completed Improvement Project
Goal: Implement Autonomous Maintenance and 5S in the Packaging workshop.
Main result: Autonomous Maintenance standards were introduced for HAAS TL, HAAS VF1 and HAAS SL.
Q4 · 2025
Q4 2025 – Completed Improvement Project
Goal: Standardize Autonomous Maintenance and 5S for Category A pilot machines through clear rules, training and tracking.
Main result: Completion of the Autonomous Maintenance plan rose from 69% to 100%.
TVH Bulgaria Ltd.
2025Q1 · 2025
Q1 2025 – Completed Improvement Project
Goal: Implement 5S and improve material flow in the Kits Department.
Main result: Annual output increased by 5.4%, or 5,676 additional assembled units.
Q2 · 2025
Q2 2025 – Completed Improvement Project
Goal: Implement 5S and improve the value-added flow in the Electric Motors unit.
Main result: Lead time fell from 696 h to 528 h.
Q3 · 2025
Q3 2025 – Completed Improvement Project
Goal: Implement 5S and Lean principles in the Cylinders unit.
Main result: The 5S audit score rose from 50 to 97 points.
Q4 · 2025
Q4 2025 – Completed Improvement Project
Goal: Implement 5S and Kaizen in the Warehouse Department to optimize space and avoid unnecessary costs.
Main result: Future costs of €50,000 were avoided.