Étude de cas: Comment un constructeur automobile allemand a réduit les coûts de harnais de 40%
Dans 2023, Un grand constructeur automobile allemand a été confronté à la hausse des coûts et aux inefficacités de sa production de harnais de fil. Avec plus 200 Variantes des véhicules et augmentation de l'électrification, La complexité des conceptions de harnais avait montée en flèche. The company initiated a cost-reduction program focusing on modularity, supplier optimization, and automation.
Challenges Identified:
Fragmented supplier base with inconsistent pricing
High labor costs in manual harness assembly
Delays due to lack of design standardization
Solutions Implemented:
Modular Harness Design: Engineers restructured the harness system into modular components, allowing reuse across different models.
Supplier Consolidation: The firm reduced its supplier base by 60%, negotiating better volume pricing with fewer, more strategic partners.
Nearshore Production: Labor-intensive tasks were shifted to Eastern Europe, cutting assembly costs by 25%.
Digital Twin Implementation: Using 3D modeling, errors were identified pre-production, saving on rework and material waste.
Results:
Total harness costs reduced by 40% sur 18 months.
Lead times cut from 12 weeks to 7 weeks.
Quality defects dropped by 35%.
This case demonstrates the power of strategic sourcing, modular design, and smart manufacturing in managing the growing complexity of automotive wiring.