Starting points for more flexible production in the automotive industry

Von Dr.-Ing. Uwe Steinkötter, Partner, ROI-EFESO

In the still highly competitive automotive industry, modular production promises more flexibility – to be able to react more quickly to market changes, to use resources more efficiently or to reduce costs. For this purpose, three aspects are crucial for success: achieving flexibility through standardization, increasing efficiency with modular, automated systems – and using standardization as a strategic operational tool beyond production. 

Increased flexibility through standardization

Highly interlinked plant and machinery are commonly the first hurdle to flexibility that factories face. In the case of automotive suppliers, such production lines are often tailored to the requirements of a single manufacturer. Or they have been specially designed for him and modified over the years according to his specifications, which further limits their adaptability. However, modular production platforms with decouplable stations are in keeping with the times, so that different vehicle models (at the OEM) or different OEM components (at the supplier) can be manufactured on the same line. In both cases, this requires consistent standardization of the tools and components in order to facilitate the changeover to different product types and / or variants.

Suppliers can also serve various OEMs with a flexible production line without incurring high customization costs. Improved responsiveness to changes in demand is another flexibility goal for the entire industry. This can be achieved by reducing set-up times, among other things. The challenges of the past – long changeover times and high downtime costs – must therefore be overcome through strategic planning and optimized processes.

Increased efficiency through modular systems and automation

The second key dimension of modular design is the retrofitting or acquisition of new machines and systems. Companies should make their decisions based on efficiency criteria in order to minimize their investment costs with standardized and flexible machines while maintaining high productivity. At the same time, they should integrate existing, old machines into these new concepts in order to realize re-use potential. Technologies that have already been in use for years do not necessarily have to be ineffective – the right combination of old and new technologies can optimize the overall system and reduce the complexity of the technological infrastructure.

Of course, efficiency increases are closely linked to progress in the digitalization and automation of a plant. With IoT-enabled machines, for example, many companies are already collecting and using data efficiently to improve their production processes. However, automation shouldn't come at the expense of flexibility. Technical solutions must remain adaptable so that adjustments can be made quickly. Overall, it is worth taking another look at the guiding principles of the Toyota production system, which relies on a high degree of individual responsibility and flexibility instead of rigid interlinking.

 "The right combination of old and new technologies can optimize the overall system and reduce the complexity of the technological infrastructure."

Standardization as a strategic tool

Particularly in the context of e-mobility and industrial sustainability, the modularity described above offers the opportunity to react flexibly to new requirements. Standardization will not only be necessary in production, but also in the development of batteries and other new technologies. It is therefore worth extending the idea of using standardized modules beyond assembly in order to make the entire value chain more efficient and reduce dependencies at the same time.

Standardization should therefore – thirdly – not be seen as a restriction, but as a strategic tool. The internal discussion about this must begin with product development. Companies should check which components are actually needed and how existing designs can be simplified. Finally, a lower number of variants also leads to lower costs and more efficient production. Ideally, this approach will be extended to other areas of operations, such as the standardization of warehouses, the technology for transport and tracking systems or sample and tool construction.

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All in all, the said aspects make it clear that the modular design of assembly lines is more than just a response to current challenges; it can be seen as a strategic necessity for the future of the industry. Companies that have already implemented a modular approach benefit significantly from the advantages mentioned. This topic is therefore of vital importance if we are to meet the challenges of the coming years and if we are to remain competitive.

Further topics:

Operations Excellenz in the automotive sector >

Modular equipment in the Future Factory >

Case Study: standards for operational excellence in an international factory network >

Autor

Dr.-Ing. Uwe Steinkötter, Partner, ROI-EFESO

Dr.-Ing. Uwe Steinkötter has extensive knowledge of lean implementation and about the realization of transformation strategies in the manufacturing industry. Prior to joining ROI-EFESO as a partner, he worked for the Bosch Group. There, he held several leadership positions in Operational Excellence, Lean Management, digitalization and transformation in the mobility, consumer goods and industrial technology divisions of Bosch.