Integrated Product & Process Development

We build bridges between product and process development in order to enable the realization of innovative products in the shortest possible time.

From design to production – we help you seamlessly connect your development and manufacturing processes.

Manufacturing companies rely on the development of innovative and differentiated products in highly competitive and increasingly saturated markets. As a result, they are faced with the challenge that with the diversity of products and production processes, production costs also rise. Integrated product and process development helps reduce these costs. It aims to develop not only functional but also production-ready products by integrating production managers into the product development process and taking their product requirements into account. We therefore support you through cross-functional requirements management as well as maintaining high product and process standards whilst reducing production costs.

Key questions

Reference projects

Client
Premium-OEM (Germany)
Target
  • Reduction of production costs as well as increase of cross-plant production quality
  • Production-driven innovation push into the vehicle projects and plants
APPROACH
  • Identification of relevant stakeholders
  • Benchmarking of existing approaches towards standardization of production processes as well as production-driven control of product development
  • Workshop-based development of the modular process concept
    • Definition of Roles and responsibilities
    • Detailed development of process steps, including preparation, approval, implementation and adherence
    • Specification of a software tool
  • Coordination and approval of the concept in customer management circles
Achievement
  • Coordinated and approved modular concept for the standardization of production processes and co-design of the product landscape
  • Identified cost saving potentials through complexity reduction of 30%
Client
Premium-OEM (Germany)
Target
  • Operational development of standards for production-oriented product design
  • Reduction of production and material costs through cross-product line standardization of production concepts
Approach
  • Establishment and temporary assumption of the modular integrator role
  • Target guidance of construction kit development
    • Implementation of concept benchmarks
    • Moderation of concept workshops
    • Recording and coordination of requirements for production and other interface partners resulting from the concept
    • Evaluation of the economic advantages of the concepts
    • Planning and coordination of the concept rollout
    • Accompaniment of the concept release in the corresponding committees
Achievement
  • Development of over 250 standards
  • Reduction of proportional production costs by 25%
  • Reduction of investment costs by 15%
Client
Tier-1 Supplier (Germany)
Target
  • Reduction of internal complexity with simultaneously high external product variety
  • Definition of the required variance
  • Determination of the economically reasonable variance
Approach
  • Development of a product and process morphology
  • Identification of variant-sensitive process steps and critical product features
  • Identification and hierarchization of constituent features
  • Definition of the product architecture and conceptual design of the modular system
    • Morphologic box for the configuration of the modular concepts
    • Development of the requirement categories
    • Derivation of the requirements
Achievement
  • Modular product system with standard variants / gradations for seven component features
  • Implementation tool for market-driven, economically optimal modular development
  • Holistic process cost database and evaluation tool for new process technologies
Client
OEM (Germany)
Target
  • Acceleration of the development process for process modules
  • Process modules define certain product properties by means of requirements, which enable the realization of optimized production processes
Approach
  • Identification of the critical path of process modularization
  • Reorganization of the process modules to coordinate and release the modules
    • Implementation of a gate and maturity level logic in order to master later changes
    • Defined connection of pre-development projects
    • Consolidation of the committees for the release of the modules
  • Implementation of a tool to enable decentralized decision-making processes and the distribution of the approved modules to the appropriate recipients
Achievement
  • Throughput time optimized process for the development of process modules
  • Acceleration of the lead time by 35%

Contact

Are you interested in a project or have questions about our services? We look forward to hearing from you!

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