Setting up internal logistics for a new automotive plant in Hungary

Client context

We worked on behalf of a car manufacturer setting up a new automobile production plant in Hungary.

We supported their logistics teams in the design, installation and start-up of all internal logistics for the assembly hall, as well as the pre-assembly and kitting areas. This start-up accompanied the production ramp-up, from 0 vehicles to 1 vehicle every 2min15sec.

Support put into place

We began by gathering all the data required for the design, based on current production at another Group plant. This enabled us to quickly test and simulate scenarios for the pre-assembly area. For logistics, we synchronized with the teams responsible for the assembly lines, in order to identify all consumption points, part numbers, variants etc.

All this data enabled us to design an initial operating mode (layout plan, flows, number of operators and logisticians, etc.), which was iterated with the teams as evolutions appeared.

Another stage of the project involved the creation, installation and adjustment of the entire physical layout: workstations, machine layout, storage and picking, small logistics trains, lineside, etc. 

Finally, we provided support for the ramp-up of production: creation of standards, visual management, reaction modes, and we trained the entire perimeter.

Results

• Productivity: + 30% (pre-assembly and logistics)

  Surface area: 30% gain in line side => productivity for assembly (not accounted for above)