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SUCCESS STORY

ELECTROSTAR lives lean - with CIP to visible results in just one week

0%

Increase in productivity

0%

Reduction of the required area

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Brief introduction of the customer

ELECTROSTAR GmbH, based in Reichenbach an der Fils, is a company with a long tradition that is internationally renowned for its high-performance cleaning solutions and as a pioneer in the field of warm air hand dryers with its starmix brand. As part of the ALGO Company Group, ELECTROSTAR has been pursuing a consistent lean strategy since 2011, which is firmly anchored in the corporate culture through continuous process optimization and employee involvement.

  • Company: ELECTROSTAR GmbH
  • Number of employees: approx. 250
  • Project location: Reichenbach an der Fils, Germany
  • Status: Existing customer

Project summary

ELECTROSTAR GmbH has successfully introduced lean production in assembly together with BeeWaTec. By switching to modular, ergonomic production solutions, productivity was increased by 18% and the space required was reduced by 33%. The new approach not only optimizes material flows and workplace design, but also promotes a company-wide, active CIP. Several assembly lines and workstations have already been implemented according to lean principles - with clear prospects for further expansion.

BEFORE

Initial situation and problems

Despite growing demand and a technological lead, ELECTROSTAR increasingly reached its limits in assembly:

  • Single-station production: inefficient processes with opposing material flows and a high level of double handling
  • Unstructured warehouse logistics: long search times, unused areas and a lack of material flow
  • Ergonomic deficits: inadequately designed workstations with high physical effort
  • Delivery capability at risk: increasing quantities lead to bottlenecks and buffering
  • High logistics costs: intensive forklift traffic and internal material movements without a clear structure

AFTER

Implementing lean production with BeeWaTec

ELECTROSTAR relied on BeeWaTec as an experienced lean partner for the redesign of its assembly processes - from concept development and the construction of modular assembly lines to on-site implementation. The basis was a flexible modular system for optimizing product flow and ergonomics. The aim was to achieve more productive, leaner production with clearly structured processes, reduced space and sustainable CIP - the new cycle production started after just one week.

Steps on the road to implementation

  • Analysis and target definition: Identification of weak points in assembly and logistics
  • Concept development with BeeWaTec: design of a new material flow and workplace layout
  • Use of the modular system: flexible, ergonomic solutions based on individual requirements
  • Rapid implementation on site: Setting up the new cycle production within a week
  • Introduction of a central assembly line: standardization with room for later adjustments and scaling

Added value and benefits for our customers

  • 18 % increase in productivity: thanks to optimized material flow and ergonomic workplace design
  • 33 % space saving: through compact, structured assembly lines
  • Less material accumulation: reduced inventory thanks to cycle-accurate supply
  • High adaptability: can be flexibly expanded thanks to modular systems
  • Lived CIP: employees actively involved, continuous improvement anchored in everyday life
  • Standardized assembly processes: clear structures for sustainable scaling of further lines

 

Herr Wachter, Project lead

„

The lean concept works for the employees - they recognize the benefits of lean production. They have seen and experienced that everything works in a structured way and that it means less stress”

0%

Increase in productivity

0%

Reduction of the required area

BE LEAN, USE BEEWATEC.

Together we realize your success story.

With BeeWaTec's lean solutions, you can optimize your production processes and sustainably increase efficiency. Our flexible and modular systems adapt to your individual requirements and reduce waste in a targeted manner. The choice is yours: we supply individual components, kits and fully assembled lean solutions. 

Here you will find your personal contact >

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