Summary
Key results
Production resumed after the complete assembly line transfer
Target performance levels achieved and the process stabilized at the new location
Recreating the process while minimizing technical risk
The client planned to relocate an entire assembly line from its facility in Germany to a new site in Poland. The priority was to restart production efficiently, recreate the key process parameters, and maintain the required quality and performance levels after commissioning. The main challenge was reproducing all critical process parameters without compromising production quality or efficiency.
The transfer required not only reinstalling the line, but also capturing its key production parameters and gaining a detailed understanding of the assembly process before dismantling. After relocation, the process had to be adapted to the conditions at the Polish facility, tested, and prepared for formal acceptance. The entire project was subject to IATF 16949 requirements for process quality and waste reduction. The client therefore needed a team that could support the successive stages of the relocation and help achieve the target quality and performance parameters.
From process analysis to line stabilization in Poland
Sii Poland supported the client as part of the transfer team throughout the successive stages of the line relocation. The work began at the facility in Germany and, following the transfer, the team continued providing on-site support in Poland.
The scope of work included:
- Analyzing the assembly process and key production parameters before dismantling the line
- Supporting process testing and commissioning after reinstallation in Poland
- Stabilizing line operations and achieving the target performance parameters
- Optimizing the sequence of operations and cycle time
- Improving process traceability, including numbering, operation records, component identification, and code scanning
- Creating a new Process Failure Mode and Effects Analysis (PFMEA) file based on the previous assessment
- Creating and updating process documentation and supporting work in the Product Lifecycle Management (PLM) environment
- Partially preparing documents and checklists and helping define key tasks and tools
The work supported the preparation of the process for formal acceptance and compliance with IATF 16949 requirements for process quality and waste reduction.
Stable line operations and greater production flexibility
Following the relocation, the client resumed production on the complete assembly line, adapted to the conditions of the Polish facility. Recreating the key process parameters, testing, and stabilization helped achieve the target performance level while maintaining the required quality after commissioning.
Process traceability was also improved – from numbering and operation records to component identification and code scanning. In addition, optimizing the sequence of operations and cycle time increased the line’s efficiency at the new location.
As a result, the process became more flexible and easier to scale or relocate, supporting further cost optimization.
Key results
- Production resumed after the complete assembly line transfer from Germany to Poland
- Target performance levels achieved and the process stabilized at the new location
- Required quality parameters maintained after line commissioning
- Higher line efficiency following optimization of the operation sequence and cycle time