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Case Studies

Tool changeover from 95 to 60 minutes: how an automotive stamping plant handled smaller batches

Lean · 3 min read · 07.10.2026

At an automotive stamping plant, we cut tool changeover from 95 to 60 minutes by breaking the changeover down into individual steps. The change was in work organization, not technology — and smaller batches became profitable as a result.

3.5 Weeks Past the Deadline: How a Special-Purpose Machinery Manufacturer Mastered Penalty-Free Deliveries

Lean · 3 min read · 26.08.2026

Client A machine-building company manufacturing custom special-purpose machines — welding, testing and assembly equipment for industrial customers. 85 employees, one shift, supplemented by on-site assembly call-outs at customer facilities.…

40 % Repeat Complaints: How an Automotive Tier 2 Supplier Stopped Closing 8Ds on Paper

Quality · 3 min read · 19.08.2026

How we helped an automotive Tier 2 supplier of welded assemblies, where 8D reports closed purely as a formality were leading to 40 % repeat complaints and a threat of CS2 escalation from the OEM customer.

Changeover from 45 to 12 Minutes: How an Engineering Company Cut Costs Without Layoffs

Costs · 4 min read · 29.07.2026

An engineering company with 240 employees was losing margin on small batches — long changeovers, overtime and a 4.2% scrap rate. The project paid for itself in five months: changeover time fell to 12 minutes and scrap dropped by 38%.