Project of the Month
"Cost-effective batch-size-one production of frame components"
More variants, less setup effort, and markedly lower cost.
THE CHALLENGE
The existing CNC technology and manufacturing processes were designed for high-volume series production and were no longer well-suited to small-batch or one-off frame components. As product variety increased, each additional reference added complexity to planning, setup, material handling, and inventory management. The result was longer setup times, excess inventory, higher unit costs, and more administrative effort. Slow-moving parts were especially challenging: they took up valuable floor space and tied up capital while contributing little to daily demand. The goal was to create a production model that combines flexibility, cost-effectiveness, and reliable parts availability while remaining adaptable to future needs.
APPROACH
- Analyzed production, part mix, organization, IT, and layout from end to end
- Evaluated the right technology for true batch-size-one production
- Built a robust target operating model: capacity, layout, and investment
- Compared implementation scenarios on a transparent cost basis
CUSTOMER BENEFITS
Series parts and C-parts now run through separate, fit-for-purpose flows. Clear operational and financial improvements support the business case:
- 70% of part references accounted for only 13% of daily demand while tying up more than 50% of inventory value, revealing significant optimization potential.
- 30% less production floor space.
- 70% fewer inventory references.
- 50% lower inventory value.
- 1,600 fewer setup hours per year.
- Payback in under three years.
From concept to realization — We help wood-industry manufacturers turn variant complexity into cost-effective, future-ready operations.