CASE study


Our tailor-made solutions can bring impressive benefits to your business and help you manage your day-to-day activities. These are the most relevant KPIs impacted by our Loss Hunter. Our tailor-made solutions can bring impressive benefits to your business and help you manage your day-to-day activities. These are the most relevant KPIs impacted by our Loss Hunter. Our tailor-made solutions can bring impressive benefits to your business and help you manage your day-to-day activities. These are the most relevant KPIs impacted by our Loss Hunter.


Benefits & impacts


Benefits achieved in the test plant:

  • a decrease of full industrial cost from 12.3 up to 8.4 EUR/unit
  • a sustainable 50% increase in production (from 92k to 135k units), and the capability to scale up to 244k units
  • a decrease in average lead time from 2.5 to 1.6 days
  • With an estimated ROI of 762 kEUR over the first year, our solution is scalable to the whole EMEA region.

On Time
On Full
Overall
Productivity
Total
Delivered
Cost

we tell you a story


1

Problem


- is an Italian company that deals with the design, application and marketing of hearing aids. It is present in 29 countries and on all 5 continents, with more than 11,000 points of sale and around 16,000 employees and collaborators, and a turnover of 1.4 billion Euros. With the acquisition of GAES plant (Barcelona, Spain) in 2018, - has consolidated its worldwide leadership reaching a global market share of 11% of the retail hearing care market.

2

Challenge


To design, validate and formalize a methodology in the Barcelona plant expandable to the whole EMEA region, with the following goals:

  • develop an earmolds integrated EMEA supply chain, capable of up to 600k earmolds per year;
  • reduce cost by 4.6 mEUR per year by improving sourcing and production effectiveness and efficiency, lowering the per full industrial cost from 13.9 to 10 EUR/unit;
  • maintain/improve current Service Level

2

Challenge


To design, validate and formalize a methodology in the Barcelona plant expandable to the whole EMEA region, with the following goals:

  • develop an earmolds integrated EMEA supply chain, capable of up to 600k earmolds per year;
  • reduce cost by 4.6 mEUR per year by improving sourcing and production effectiveness and efficiency, lowering the per full industrial cost from 13.9 to 10 EUR/unit;
  • maintain/improve current Service Level

3

Methodology


Our digital intervention has been focused on:

  • process mapping + identification of constraints, losses, current performances/capacities;
  • redesign and optimization of all processes in terms of layout, material flow and handling, capacity and organization;
  • designing an optimized scheduling model to manage unpredictable demand;
  • ensuring the digital traceability of items along the production line.

1

Problem


- is an Italian company that deals with the design, application and marketing of hearing aids. It is present in 29 countries and on all 5 continents, with more than 11,000 points of sale and around 16,000 employees and collaborators, and a turnover of 1.4 billion Euros. With the acquisition of GAES plant (Barcelona, Spain) in 2018, - has consolidated its worldwide leadership reaching a global market share of 11% of the retail hearing care market.

4

OUR SOLUTION


We have developed from scratch a Digital Twin in order to:

  • simulate all possible future scenarios, obtaining precise calculation of lead times, service levels and saturations;
  • validate the re-layout/material flow hypothesis before any intervention;
  • find the optimal configuration in terms of allocated FTEs and shifts for any possible demand which yield maximal throughput.

We have also designed an OCR-based real-time digital traceability and jobs scheduling system, integrated with the existing ERP, for guaranteeing the optimal scenario in case of unpredictable demand and jobs priorities.


Gantt chart and mandays


Our tailor-made solutions can bring impressive benefits to your business and help you manage your day-to-day activities. These are the most relevant KPIs impacted by our Loss Hunter. Our tailor-made solutions can bring impressive benefits to your business and help you manage your day-to-day activities. These are the most relevant KPIs impacted by our Loss Hunter. Our tailor-made solutions can bring impressive benefits to your business and help you manage your day-to-day activities. These are the most relevant KPIs impacted by our Loss Hunter.

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20

mandays


Our tailor-made solutions can bring impressive benefits to your business and help you manage your day-to-day activities. 

GANTT CHART
3 months for

the loss hunter IS AN ESSENTIAL TOOL FOR ANY OPERATIONS SITE DIRECTOR TO ACHIEVE OUTSTANDING RESULTS

 

Want to know more?


Whether you have any questions or need more info, we would be happy to help!


CONTACT US

Contact US

for more information write to
contact@fibonaccilab.ch


Where we are

Rue Hans-Fries 1,
1701 Fribourg, Switzerland


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