Product Machining Excellence
In manufacturing, individual machines – or in cases of exceptionally high demand, even the entire machine fleet – often turn out to be bottlenecks and significant cost drivers. Moreover, replacing machinery and equipment is capital-intensive, resulting in a direct negative impact on cash flow.
Therefore, enhancing the performance of existing machines and equipment plays a central role in EFESO’s product excellence initiatives. With a holistic approach to cycle time optimization and increasing the OEE of existing machinery, we achieve significant improvements without additional CAPEX investments. In doing so, we rely primarily on two particularly advanced, self-developed and refined methods: video analysis and “Software-Based Machine Tuning.”
AI-Based video analysis in manufacturing
The video analysis uses AI-powered software for time-synchronized camera sequences and multi-image analysis, which has already been used in more than 600 analyses. It is ideally suited for analyzing environments with numerous machine movements or peripheral activities (e.g., robots) – in machining, assembly, and any kind of automation across multiple industries.
Our project footprint in video analysis
This type of video analysis can identify and evaluate weaknesses and optimization potential with exceptional depth. In general, five application areas can be defined where video analysis provides particularly significant optimization leverage:
The value of using video analysis is demonstrated by the following example:
PROJEKT EXAMPLE
Video analysis of existing infrastructure enables an increase in output of at least 9%
Initial situation
Challenges in a series or large-scale production:
- Urgent need to increase capacity
- Reduction of cycle time
- Bottlenecks in the manufacturing process
- Capacity requirements for new products (identify performance reserves)
- Quality optimization (e.g. high reject rate)
- Availability problem (unplanned downtime due to process problems)
Approach / method
- Multiple camera installation & video recording
- Sequencing with video-analysis tool
- Idea documentation, based on micro potentials
- Review of ideas with customer team
- Implementation plan development (including realization)
Customer Value Added
Software-Based Machine Tuning in production
“Software-Based Machine Tuning” is a specialized method for improving the cycle times of existing CNC machines without additional investments in hardware. Following a preliminary analysis of the machine software, an additional solution is installed that enables adaptive control and AI-supported real-time data analysis.
Our project footprint in Software-Based Machine Tuning
The following example illustrates how existing potential can be fully maximized:
PROJECT EXAMPLE:
software-based machine tuning
Initial situation
Challenges in a series or large-scale production:
- Urgent need to increase capacity
- Reduction of cycle time
- Bottlenecks in the manufacturing process
- Capacity requirements for new products (identify performance reserves)
- Quality optimization (e.g. high reject rate)
- Availability problem (unplanned downtime due to process problems)
Approach / method
- Quick check and pre-analysis of machine software
- Offline preparation of software installation
- Software installation and implementation of tools at the machines for adaptive feed control with smart real-time data analysis
- Cut-check data to confirm efficiency improvement
Customer Value Added
CONTACT
End-to-end solution portfolio for product excellence
CASE STUDIES & INSIGHTS - PRACTICAL EXAMPLES
Capabilities for Performance Improvement in CEE region
INSIGHT:
Learn more about EFESO’s ‘Performance Programs for the CEE Region’ and the seven levers for performance optimization.
Performance Booster
INSIGHT:
Identify bottlenecks, resolve them effectively – and boost results fast.
By optimizing machines and equipment, companies can increase output quickly while achieving long-term cost reductions. A targeted approach that directly impacts competitiveness and performance.
Margin Maximizer
INSIGHT:
Learn how the EFESO ‘Margin Maximizer’ helps leading companies to secure their profitability in times of upheaval.
Factory Planning – Time for Performance Programs
INSIGHT:
EFESO supports companies in the end-to-end realignment of their production network – from ideation to ramp-up. As a one-stop shop, we offer strategic, efficient, and hands-on support for every stage of your factory planning.
Integrated Costing
INSIGHT:
With progressive cost management and proven tools to improve profitability, EFESO helps companies strengthen their financial performance – even in challenging and volatile market environments.
EV Launch Management
INSIGHT:
With EFESO’s integrated EV Launch Management approach, manufacturers can manage the development and market introduction of new vehicle series more securely, efficiently, and profitably – accelerating their path into the electric future.
End-to-End Inflation Management
INSIGHT:
Learn how to sustainably increase profitability through comprehensive inflation management.
With an integrated approach, EFESO helps suppliers recover inflation-driven costs and strengthen their position in the value chain.
End-to-End Claiming Process
INSIGHT:
Read here how EFESO’s team can help you to professionalize your receivables management and make your organization more agile and more resilient to phases of inflation/deflation.
Holistic Profitability Programs Automotive Industry
INSIGHT:
Discover how one Tier-1 supplier is expanding into the fast-growing e-axle sector, closing a profitability gap, and meeting customer-specific design requirements through a best practice project with EFESO.
Profitability Improvement via Change Management
INSIGHT:
Driving profitability through change:
With its Commercial Change Management Process (CCMP), EFESO helps Tier-1 suppliers in the automotive industry align pricing, cost, and customer demands – for measurable results in a dynamic transformation environment.