ケーススタディ: ドイツの自動車メーカーはどのようにしてハーネスのコストを削減したか 40%

で 2023, ドイツの大手自動車メーカーは、ワイヤーハーネス生産のコスト上昇と非効率性に直面しました。. オーバーで 200 車両のバリエーションと電動化の増加, ハーネス設計の複雑さは急増しました. 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% 以上 18 months.

Lead times cut from 12 weeks to 7 週.

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.