Optimization of Production Processes at an Automotive Equipment Manufacturer

As part of an audit and optimization mission, ATP Graywerks supported an automotive equipment manufacturer in the Lyon region in redesigning its assembly lines. The main objective was to reduce unplanned downtime and improve Overall Equipment Effectiveness (OEE).

Our team first conducted a thorough diagnosis of production flows, identifying several bottlenecks related to inadequate workstation organization and insufficient preventive maintenance procedures. In collaboration with the client's technical teams, we implemented a structured action plan around three axes: reorganizing workstations according to Lean Manufacturing principles, implementing a preventive maintenance system assisted by IoT sensors, and training operators in best practices for safety and quality.

The results were significant: machine availability increased from 72% to 89% in six months, scrap decreased by 34%, and the compliance rate of produced parts reached 99.6%. Furthermore, team engagement strengthened thanks to better visibility of real-time performance indicators.

This mission illustrates our ability to combine technical expertise and human support to sustainably transform industrial processes.