Up to 50% reduction in production costs

To give you an idea of what financial implications the application of the FleXlean concept may have for you, we have taken a few figures from an actual case and laid them out for you.

The product
A cup with a screw top consisting of the following parts:

• cylindrical metal cup with plastic rim
• 2 screw inserts
• 2 screws
• end product dimensions: approx. 200mm x 60mm (d x h)
• mass approx. 2.5 kg

Functions
The following process steps must be carried out:

• bulk supply of cups
• placement in holder
• transport
• bulk supply of inserts
• hot pressing inserts into cup
• transport
• bulk supply of screws
• screw in screws
• transport end product

Points of departure

• production currently located in your own country, will also be in the future
• approx. 10,000 products per shift
• 2 shifts a day and 5 days a week
• production required for approx. 3 years
• current semi-automated means of production are valued at approx € 80,000
• operator/wage costs; some skill and experience required and an income of approx 15% above minimum wage.
• We estimate a conventional production line of approx € 235,000

Outcome:

to reduce your production overhead by 50%!
The assembly costs per product are:

• Current situation with a semi-automated line: 6.63 euro cent (2 operators per shift)
• A fully automated production line designed to be product specific: 4.39 euro cent
• The FleXlean concept: 3.55 euro cent