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Process Optimization at Automotive Supplier FTE Automotive

Case Study

Challenge

At the main factory of FTE Automotive, processes needed to be professionalized in production and organization, and state-of-the-art manufacturing methods introduced. As part of this innovation project, the rapid implementation of new technologies and new methods of visual process management had to be synergistically implemented. 

Success

Product quality standards were maintained at all times. 

Interview with Walter Beck, Factory Manager at FTE Automotive

What does FTE automotive stand for as a company?

The company has many years of experience in the production of brake and clutch hydraulics. FTE automotive products are in demand worldwide and our OEM customers see us as a strong partner for their innovation projects. Behind our quality and innovative products lies a highly qualified, creative and motivated team. 

 

"Our goal is to work with the latest production methods and to ensure a high degree of product innovation and quality for our customers."

You want to know what Atreus can do for you in a similar situation?
Contact Dr. Harald Linné, CEO.

+49 89 452249-200 Harald.Linne(at)atreus.de

"ATREUS provided us with suitable experts just a few days after our inquiry.

This flexibility is an important foundation for future-oriented growth planning."

What was the situation when you called in Atreus?

As a traditional company, FTE Automotive is also distinguished by the fact that the majority of our employees have been with us for a long time. This tradition ensures experience and stability. Nevertheless, it is important – through external support as well – to regularly review the company’s internal processes and, where appropriate, to make them more effective. That’s why we deliberately opted for an external production expert and innovation manager to support and optimize these processes. 

What requirements did you place on the interim manager?

The base requirement was for a senior manager with strong implementation and communication skills and a hands-on mentality. An engineer with a focus on manufacturing or production engineering and extensive experience in the areas that affect our production. 

"The Atreus manager succeeded in inspiring the production process optimization team. That was a key success factor. Everyone was highly motivated by him over the course of the change processes."

Short-term successes

  • Increased efficiency
  • Reduction of product throughput times
  • Reduction of WIP by 25%

What tasks awaited the Atreus manager?

The main task was to structure and optimize manufacturing processes at our company headquarters. This involved around 300 employees and a turnover of € 50 million. It was necessary to ensure that the entire team was trained in new methods of visual process management while continuing production and fulfilling FTE quality requirements. 

"On the new, high-tech processing machines, we have increased OEE to over 80 percent."

What characterized the cooperation between the interim manager and the on-site staff?

The interim manager very quickly won the acceptance of factory staff through his knowledge and team spirit. He recognized the weaknesses in production and optimized them through his active support and personal example. As a result of his regular attendance at the weekly master craftsmen meeting or on-site process visualizations, the optimizations introduced were quickly assimilated into the production chain. 

Which concrete successes were achieved through the project?

In just a few months, through the efforts of the Atreus manager and the newly implemented production technologies, we succeeded in significantly improving profit center earnings. 

Atreus is the leading interim management provider in Germany and one of the largest in its field in Europe. We solve difficult operational management and transformation problems quickly and reliably. Contact us and find out how we can help you master your situation with management expertise that is available at short notice and that is the perfect fit for you.

Atreus is a co-founder of Globalise – the market’s leading and largest provider of international interim management. Accelerating change and delivering success. Worldwide. Structured as a global group of leading interim management firms, Globalise has the reach to support you in solving your company’s most important issues around the world.