References

Real Projects. Real Responsibility. Real Outcomes.

A selection of our relocation and industrialisation projects – without client names for reasons of confidentiality.

Automotive Components & Systems

Selected projects

Automotive · Interior

Challenge: Relocating series production to a new site in the middle of the launch – without access to the previous supplier’s tools, in just 6 months.
Our solution: Interdisciplinary relocation team on site, tool and fixture rebuild based on part and specification, VDA 6.3 audits, full sampling/PPAP.

6 monthsFull security of supplyVDA 6.3 / PPAP

Automotive · Chassis

Challenge: Creating transparency on costs, quality and risks across the entire supply chain and actively optimising cost structures.
Our solution: Integrated supplier management, best-cost-country sourcing, make-or-buy analyses; relocations to Italy, North Africa and the Czech Republic.

Second supplier establishedRobust business caseZero-defect strategy

Automotive · Powertrain

Challenge: Reliable standard times and line balancing across 15 main workstations with a high number of variants (AWD, hybrid, M/E shift).
Our solution: Work content and time analysis per station, RFID workpiece carrier control, multiple nutrunners, poka-yoke and test concept.

120 s cycle time15 main workstationsFull traceability

Automotive · Body

Challenge: Transfer of approx. 39 tools and welding fixtures for approx. 150 parts – with missing documentation.
Our solution: Complete tool documentation and inventory, condition check, 8D-driven quality assurance at the new supplier.

~150 partsNo line stoppage8D & sample approval

Automotive · German OEM

Challenge: Integrating new model series into running production without downtime, on time and on budget up to start of production.
Our solution: As-is analysis, digital factory with DELMIA, robot simulation, layout and logistics planning, launch support incl. CE and acceptance.

0 downtimeDigital twinAcceptance at SOP

Automotive · Automation

Challenge: 17 s cycle time, ~850,000 parts/year, 98 % availability and automatic changeover for 9 screw sizes.
Our solution: Design of the screwdriving/assembly stations, build and machine capability test at the manufacturer, relocation, recommissioning and final acceptance over ≥ 10 shifts.

Cmk ≥ 1.67Cpk ≥ 1.3398 % availability

Automotive · Reshoring

Challenge: Reshoring from a low-cost country while supplying the OEM – in parallel with industrialising the successor model.
Our solution: Process and tool transfer, re-qualification to IATF 16949, in-house assembly machines, brazing technology and series testing.

0 days line stoppageIATF 16949Lower logistics CO₂

Automotive · Complete vehicle

Challenge: Very short development times in a complete vehicle project (18 months) and brand-specific cockpit adaptations.
Our solution: Recovery and escalation management, control of tier-A suppliers, make-or-buy decisions, relocation of injection-moulded parts during launch.

18 monthsTier-A suppliersRecovery management

Industries

OEMs and tier-1 suppliers: interior, powertrain, chassis, body, e-mobility.

Avionics, electronics recovery, mission-critical components and complex system integration.

Automation, precision manufacturing, scalable series processes.

Whether mechanical design, a plant relocation, an electronics redesign or an AI pilot – we will get back to you quickly with a concrete proposal.