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Optimization of Material Flow and Savings of Space at Valeo Automotive

The Valeo production facility in Wemding produces electronic components for car manufacturer. Due to growth in volume and diversity of products on one hand side and restrictions in space on the hand side there was a need to optimize the material flow.

The link between semi finished products and final assembly should be improved in the sense of reduced materials on the shop floor and improved lead times. This should generate more flexibility to react on changing demands.

We started with 5S workshops to achieve 20% reduction of space required. This free space was used to install Kanban areas directly on the assembly line. Also additional storage locations have been eliminated.

To empower the shop floor people as well as administrative areas the 5S workshops have been extended to the order management office areas. This was sign to all involved people to bring their ideas into the change process.

“Red card” activity in administrative ares and direct implementation of improvements described on control boards.

Defined Kanban areas on the shop floor.