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SUCCESS STORY

ELESTA GmbH - Lean as lived practice

Process time per day

reduced by 60min

First-pass yield

significantly improved

20% less space required

per workstation



Brief introduction of the customer

ELESTA GmbH in Bad Ragaz is one of the leading manufacturers of relays with forcibly guided contacts and functional safety sensors. With around 350 employees and highly integrated in-house production, the company has been focusing on quality, safety and efficiency for years. As a lean pioneer in Switzerland, ELESTA began its journey of continuous improvement back in 2005 - a journey that continues to this day.

  • The company: ELESTA GmbH
  • Number of employees: approx. 350
  • Project location: Bad Ragaz, Switzerland
  • Status: Long-standing customer

Summary of the project

Lean is not just a buzzword at ELESTA, but a lived practice. With modular BeeWaTec components, solutions are created directly in the company's own CIP workshop: fast, flexible and precisely tailored to requirements.

Trained teams from production implement ideas from the store floor independently. The result: improvements that stabilize processes and relieve employees at the same time.

BEFORE

Established process with new requirements

The semi-finished assembly of the contact sets, which are later integrated into relays in other assembly lines, was functional and fulfilled its purpose. The assembly line was analyzed in a GEMBA workshop. The employees identified potential for improvement in the areas of work ergonomics, area productivity and pulling order control.

In future, order management is to be transferred from the team leaders to the employees. This will improve throughput times and responsiveness, and increase self-organization and responsibility on the assembly line. In addition, the processes are to be made more transparent so that they can be adapted more easily to other processes. Furthermore, the planning of contact set variants had to be taken into account in the new process.

The challenge was the consistent further development of an established area - with the aim of further improving time, space and quality.

AFTER

Ergonomic modules and customized Kanban solution

The project was planned according to a SMART brief and implemented within one workshop day. The short implementation time was possible thanks to the easy handling of BeeWaTec's modular tube connector system and the wide range of connection techniques that allow quick adjustments without complex designs. This flexibility supports the employees in the line in implementing solutions directly on site according to their requirements.

After one month, a structured effectiveness test was carried out using defined characteristics to ensure the sustainability of the solution and make its success measurable.

Implementation with method

  • CIP workshop: Fast, independent optimization directly at the workplace
  • Modular standards: Flexible adjustments to heights, depths and layouts
  • Idea management: integration of suggestions from apps, Gemba and store floor management
  • 80:20 principle: focus on pragmatic solutions for quick results
  • KARAKURI lifting stations: Mechanical ergonomics solutions (developed and built by BeeWaTec)

What has been achieved?

  • New ergonomically optimized line modules
  • Implemented in close cooperation with employees and according to their results
  • Kanban flow rack, which corresponds exactly to the pulling production concept and is designed in such a way that it can be filled independently by the users with the right materials at the right time, according to customer requirements.

The results:

  • 60 minutes less process time per day
  • Significantly improved first-pass yield
  • 20% less space required per workstation
  • Improved ergonomics and noticeable relief for employees

Added value and benefits for our customers

  • Flexibility through modular solutions according to ESD standards
  • PDCA-supported CIP with BeeWaTec modular system
  • Independent optimization by employees
  • Support with complex special solutions
  • Noticeably better ergonomics and occupational safety


Amire Destani ELESTA

Amire Destani, Team Leader Production Relays

"

We use BeeWaTec's modular tube plug-in system in almost all areas - from transport trolleys for internal logistics to planning boards in the offices and brackets for WLAN modules. The flexibility and ease of use make it easy for us to continuously optimize our workstations and processes."

Process time per day

reduced by 60min

First-pass yield

significantly improved

20% less space required

per workstation

BE LEAN, USE BEEWATEC.

Together we will 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.

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