UTConsult

Project Selection

• CO2 project
  • Analyze CO2 footprint of a Chinese factory
  • Develop an action list to significantly decrease the CO2 output of the plant
  • installation of a solar system (approx. 30% of the total electrical power consumption)
  • develop a CO2 optimized solution for the replacement of the existing AC solution in the office building and an optimized solution for an AC system in the workshop
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• Finished Warehouse reorganization
  • Increase the finished goods turn over by 30%
  • Reorganization of finished warehouse processes
  • Investments in layout, storage tools and buildings
  • Reorganization of organization-chart
  • After analyzing an action plan was developed and approved.
  • Partly investments in layout, building and warehouse equipment were finished. Partly the investments will be done during next month.
  • An effective stock management system for the reduction of dead stock, slow moving stock and old stock (quality) was developed and implemented.
  • Analysis, Actions for critical products were and will be defined and followed up monthly.
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• Sales Reorganization in the Chinese market – project member
  • Sales Reorganization
  • Market analysis of different Chinese industries with task to find potential new customers by using already available products or products to be customized
  • replacement of head of sales
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• Approval process of an existing Chinese plant w.r.t. environmental and throughput
  • Some years ago, an announced machine capacity increasement was executed. The local government denied several times the final approval and came up with new demands.
  • Developing technical solution in cooperation with the local government, Chinese associations, and Chinese Universities
  • Change the production processes to solvent free (no solvents are used anymore to support the production process)
  • Implementing and executing an exhaust system project - 3 different exhaust systems (Invest amount > € 1 Mio.) for filtering solvents (chemical reactions during production process), cleaning living water and industrial water
  • Installation and start-up in cooperation with the local government
  • Final approval for the exhaust systems and the increased throughput – no risk of shortly closing the plant any longer
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• New Production line in existing plant in China
  • Collecting legal demands for getting investment acceptances from local government
  • Developing production technology together with supplier, engineering and R&D (investment amount > € 4 Mio.)
  • Currently the project is in the start-up phasis.
  • The project follows schedule and investment budgets. Currently the project in the status of commissioning
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• Energy optimized steam production
  • Collecting legal demands for getting investment acceptances from local government
  • Engineering a modern steam production system (Investment amount > € 0,6 Mio.)
  • Installation and start-up in cooperation with the local government
  • Specific energy consumption per production unit reduced by more than 30%
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• Automatization of a manual workplace for weighting small amounts of chemicals
  • Collecting legal demands for getting investment acceptances from local government
  • Engineering a modern semi-automatic weighting machine with automatically data transfer between the machine and the existing ERP system
  • Installation and start-up in cooperation with the local government
  • The system works in mass production without complaints
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• Localization of raw-material supply to avoid possible supply problems
  • In the past the company faced some financial (anti-dumping, tax-value changes, logistical cost changes) and availability (customs, long lead time, less flexibility) items.
  • Leading of several replacement projects, partly in cooperation with OE customers
  • leading engineering change projects for replacing raw-materials in serial products – OE automotive
  • Availability problems are mostly gone
  • Significant cost reductions (several hundred k€ per anno)
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• Quality control of e-scooters
  • Developing of quality criteria and creating of check-lists
  • Carrying out quality checks before delivery
  • Mostly no complaints on assembly and transport issues
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• Turnaround of a development and manufacturing site in China
  • Implementation of cost reduction and efficiency improvement projects in all business areas, implementation of KPIs and reporting
  • Break-even reduced by more than 30%
  • Alignment of business processes to the request or OEMs Automotive
  • Company fulfills requirements according VDA6.3 and started serial delivery to an international OEM Automotive
  • Expansion of local development investments in test field, LAB and training of staff with the aim of development in the region for the region
  • Development of several new product families, qualification of local supplier in the raw material area
  • Margin development from – 5 % to + 12 %
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• Restructuring and reorganization of an engineering company in the project business
  • Reorganization of operational processes after implementing a social plan
  • Implementation of a functioning project management system
  • Company supplies its customers with reliable schedules and estimated costs
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• Restructuring production network of 5 plants
  • Development and implementation of a production system with the elements of production control, tied-up capital, quality assurance, staff training, key performance indicators, cost management, maintenance (TPM) and material flow
  • Reorganization of production overheads, clear responsibilities / competences and resource allocation
  • 2 of 3 critical production sites produce on schedule or ahead of plan in compliance costs or below: productivity increase of approximately 10%
  • By closing the project, a Task Force for the 3rd location was installed and some improvements were executed
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• Building strategic customer-supplier relationships with the objective to generate optimized cost structures
  • Developing and implementing improvements in the subject’s costs, logistics, quality and technology (supplier profile)
  • Delivery rate and quality ratio > 99%
  • Significant increases in volume over the previous year
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• Machinery investments (seven-digit capital value) in sorting technology in recycling industry
  • Budget and deadline compliance
  • Significantly improved qualities with improved separation efficiencies
  • Yield increase > 20% per unit produced
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• Factory start-ups in Brazil and China, factory relocation in the U.S. connected with know-how transfer and the establishment of an international procurement network
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• Insolvency of a strategic Chinese supplier
  • Restart the Chinese production in-house under high timing pressure
  • Restart after a few weeks - avoid high penalties, avoiding loss of sales
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• ERP selection and implementation
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• Market development
  • Investment implementation and commissioning of one of the most advanced powder coating plants in Europe (with heat recovery and setup time optimization)
  • Significant increase in sales volumes through the implementation of a sales campaign with trend colors
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• Part reorganization of a production site
  • Conversion of a portion to lean manufacturing, TPM and Kaizen implementation
  • Investments in setup time optimization
  • Investments in special purpose machinery to increase product variety at vastly reduced lot sizes
  • Delivery rate increase > 10 %, increasing the product variance > 40%, reduction of tied-up capital > 30%
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• Turn around in the relationship with an international OEM
  • Improvements in the areas of logistics (JIT), quality (FPY), cost and technology
  • Maintaining and expanding the business relationship (turnover > € 10 m€/annum)
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• Ramp down (staff reduction of 50 % within a short time) and ramp-up (more than doubling of the staff within a short period)
  • Restructuring, reorganization, implementation of measures to prevent the bullwhip effect along the strategic supply chain
  • Maintenance of the supply chain during a market crisis
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• Supplier development
  • Develop and implement a strategic supplier development program
  • Cost savings in procurement (seven-digit, material availability > 99%, quality level > 99%)
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• Efficiency Project
  • Rationalization investments and expansion investments in machinery and equipment (seven-digit capital value)
  • Cost savings and additional revenues in seven-digit range
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• New Products
  • Development, design and implementation of an investment to produce high-quality granules
  • Additional revenue in the high six-digit capital value
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• Efficiency Project
  • Configuring and installing a compacting machine to produce solids from dust. Dust had to be disposed of as waste. Solids can be processed and sold as granules
  • Cost savings and additional revenue in seven-digit range
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• Packaging Project
  • Development and use in serial production of a water-repellent packaging material made ​​of paper for packaging and storage of re-condensing products in non-air-conditioned rooms. Replacement of packing in PE
  • Cost savings in recycling fee taxes in the mid-six figures
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• Machinery relocation
  • Relocation of machinery and equipment from international subsidiaries into the mother plant with the aim of increasing efficiency
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• Organizational development
  • Introduction of group work in the production floors connected with a newly developed system of premiums
  • Increase the quality and delivery performance ratio > 98% cost savings in maintenance (six digits), improve productivity > 10%
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• DIN ISO 9001, 14001 and 45001 implementation and revalidation
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