Best practice assembly and logistics

Modern assembly systems are capable of manufacturing complex and multi-variant products at competitive costs. They are capable of individual production and small series and are flexible with regard to fluctuations in the number of pieces. This also applies in a differentiated form to series production.

ROI Management Consulting has the necessary tools at its disposal:

With ROM®, the ROI operation sequence method, a waste-free assembly system is simulated in a short time on the basis of the parts list. Optimal assembly time and potential are thus determined.

The assembly system itself is developed from a best-practice modular system based on the following basic principles:

  • clear separation of assembly and logistics,
  • Introduction One-Piece-Flow,
  • flexible timing,
  • Optimal separation and integration of pre- and final assembly,
  • reasonable automation, low cost intelligent automation,
  • Use of industry 4.0 technologies,
  • Pull principle and flexible retooling in parts supply,
  • standardized replenishment processes,
  • modular and use-neutral assembly system and workplace design,
  • team-oriented and capacity flexible organizational concepts
  • Ergonomically designed workplaces
  • Electric forklift vs. diesel forklift (CO2 issue)
  • Digitalisation as the basis for efficient and thus resource-saving processes
  • Occupational safety (accidents, hazardous substances, ...)

In addition, ROM® can provide valuable input on aspects relevant to production and assembly which should already be taken into account in the product design phase.

Zwei Männer in einer Industriehalle
©A Lot Of People/©Kzenon/

Case Study

Bild einer Maschine in der Autoindustrie

Quality improvement in the automotive industry

A leading global automobile manufacturer wanted to mobilise and accelerate its entire network of nine factories in terms of cost and quality. To this end, the transfer of know-how between the plants was to be improved.

Case Study

Close-up einer Maschine

Cost reduction/restructuring due to market changes

Sales successes secured pole position for a company in the plant construction and mechanical engineering sector. However, this was extremely at risk: a significant margin erosion with unchanged sales and well-established structures required major changes in a short period of time.

Case Study

Bild einer Industrienaemaschine
©HelloRF Zcool/

Reducing complexity/Standardisation

Reduce variance and complexity within the product portfolio in the highly specialised textile machinery construction market. Key objectives: Cost reductions and strengthening the position in the Chinese market.

Case Study

Bild eines Laborarbeiters in der Elektobranche
©ARRI Group

Quality in production

A medical technology company had to reduce the number of errors on the production line for one of its top products by a factor of ten. Strict market regulations limit the means at their disposal.