Part 3: The standardized modular factory in practice taking the example of an automotive supplier

In the first two parts of our series, we initially illuminated the requirements of factory planning in times of change and the theoretical concept of the standardized modular factory. Now we will discuss the possibilities of practical implementation taking the example of a car wheel rim refiner production.
- Installation of a standardized modular factory for revolutionary technology for the refining of aluminum rims by way of mechanical surface processing;
- An iterative planning process permits the development of flexible implementation variants and dynamic adaptations to the market demand;
- Planning taking into account modularity of the buildings for flexible adaptation to different area forms
The standardized modular factory in practice: A case study from the automotive sector
At the end of our blog series about the standardized modular factory, we will discuss a case study illuminating the potential and practical implementation of the concept of the standardized modular factory in automotive parts manufacturing. The objective of this study was to elaborate a model factory for surface finishing of aluminum rims by using an innovative technology allowing consistent mechanical machining. This technology will revolutionize the branch by setting new benchmarks in terms of quality, cost and productivity. This innovation can only be successful with a product solution to be realized quickly and expanded flexibly, without interrupting the day-to-day operations. These requirements resulted in the standardized modular factory conception allowing gradual capacity expansion and global scaling of the factory structure. The focus was on launching the new technology to the market quickly and gradual breaking into international markets by way of the standardized modular factory as a scalable production model.
Product and innovation: New benchmarks in surface finishing
The aluminum rims processed in the standardized modular factory constitute the heart of the innovation. These products are available in different design variants, for example light-metal cast and light-metal forged rims; in addition, special constructions are available, such as multipiece or hollow spoke wheels. Whereas, on the one hand, the differences in the rim design and specifications influence the machining process, on the other hand, the main innovation is the introduction of a mechanical grinding and polishing process. This technology replaces the work that has been done manually to date which results in significant cost reductions and continuous quality increase. This process innovation is completed by the innovative acrylic-based powder coating giving the rims a self-cleaning surface. This coating protects the rims not only from stone chipping, but also ensures that no dirt and brake dust get stuck on them. This combination of process and product innovation represents a unique feature for the standardized modular factory and promises an essential added value for the customers in the automotive industry.
Iterative planning process: The way to the optimal standardized modular factory
The standardized modular factory was planned and implemented within an iterative process with integration of both technological and organizational aspects and considerations of the buildings. Starting out from an ideal factory building structure, this planning approach was based on the development of step-by-step expansion variants promising cost-effective production. These implementation variants were designed to permit continuous growth, with the focus put on minimization of the unit costs. The planning process was started with defining the standardized modular factory as a reference model that was then used as the origin for all further planning. Subsequently, different implementation variants were defined for activation in accordance with the market requirements.
Such a flexible approach allows the production capacities to be adapted to the needs dynamically and, in addition, to optimize the operating costs. The advantage of this procedure is that even in case of changes in the market demand the next steps are already planned in advance, allowing fast and safe reactions. The standardized modular factory can be scaled in an efficient manner or, where necessary, duplicated without disturbing the day-to-day operations.
Technological and organizational integration
An essential aspect in the phase of planning was the technological planning covering selection and integration of the production equipment and planning of the production processes and factory layout. The planning comprised six steps – beginning from the analysis of the demands placed on the product and the determination of the appropriate functions. This process also included an evaluation of alternative technologies and identification of the most efficient solutions for the standardized modular factory production requirements. The production equipment was dimensioned by adjusting the process times to be able to guarantee optimum use of the resources.
This technological planning formed the basis for the subsequent organizational planning during which the work processes and human resource planning were elaborated in detail. The work organization was designed to enable the existing employees to respond flexibly to different production requirements. The qualification of the employees played an important part in ensuring an efficient, high-quality production. The final layout variants were elaborated with consideration of the technological requirements and the necessities of work organization, with priority on flexibility and expandability of the factory structure.
Planning of the buildings; modularity
Another important aspect of planning of a standardized modular factory is the design of the buildings which permits a modular and flexible factory building structure. In the rim refining factory, different functional areas with different structural requirements were defined. These functional areas were clearly separated to be able to guarantee optimum utilization of the structural resources and to minimize the operating costs. Thanks to the modularity of the factory buildings, the expansion axes could be used in an optimum manner; different arrangement variants were generated to ensure flexible adaptation to different area forms.
This adaptability turned out to be especially valuable since it enables the standardized modular factory to react to changes in the market conditions quickly and efficiently. In addition, the use of sophisticated modular structural units facilitates the licensing procedures in the case of expansions or partial removal of the buildings and accelerates the ability of the factory to respond to new requirements.
A future-proof solution for the industrial production
The standardized modular factory presented in this case study impressively demonstrates how well-conceived and holistic planning can lead to flexible and efficient production solutions. Thanks to the combination of technological innovation, modular design and integrated planning, companies can react on market changes faster and, in addition, optimize their production costs. The standardized modular factory provides a future-oriented solution for industrial production which enables companies to increase their competitiveness and maintain their market position in the long term. This case study illustrates that the standardized modular factory is not only a theoretical concept, but can also be implemented successfully in practice and supports companies in meeting the requirements of modern production.
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