Comment réduire vos couts de production

How to reduce your production costs?

Lowering production costs is a question that obsesses many company managers and subcontractors. Faced with this puzzle, you can hardly be an exception to the rule. However, despite the lack of apprehension in this area, it is possible to make room for progress. Organization of work, calibration of tools, automation, training, purchasing, etc., manufacturers are forced to pull out all the stops if they want to reduce their production costs and improve their competitiveness.

Have your calibration equipment checked

Calibration verification can be done using an MES. As for data collection, specified gauges can be used for this purpose. You must take into account the actual use of the tools for effective calibration of them. There is therefore no need to comply with the classic calibration scheme backed by an expiration date. Its main disadvantage is the overriding of the calibration function. On the other hand, the other alternative allows each workstation to define and memorize the calibration frequencies in the system.

What about work organization methods?

What approach should be taken to achieve a reduction in production costs? This is the main question asked by many subcontractors. The method to use, the need to call on a consultant or even the possible solutions when you think you have tried everything are all issues that many entrepreneurs are forced to face. In general, these face several challenges. Competitiveness limits, customer requirements and a highly competitive environment, such as low-cost products, are some of them.

It’s difficult to undertake a revolution of this scale alone when you are at the head of an SME with a Tech culture. Roland Borghèse is a consultant in industrial organization at Cetim in Saint-Étienne. For him, “one of the big problems for French subcontractors is often doing a little bit of everything. For example, mixing large series at reduced prices and technological products in small series using the same means of production. Because the resulting organization is a compromise, and overall performance is necessarily average. » In the workshop, continues the expert, “cost reduction is increasingly conditioned by industrial strategy”.

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However, there is no doubt that to achieve cost reduction, subcontractors primarily rely on improving procedures. Among the companies selected as part of a survey on this topic, 80% cite process management as being an essential lever in terms of competitiveness. On the other hand, 43% of the companies surveyed consider improving industrial organization as a criterion that could impact cost reduction. Marc Sagorin is the general secretary of Sifcor, the French leader in forging. “Product/process innovation, he assures, remains the major lever for cost reduction”

Consider renewing your equipment to stay up to date

Many managers have chosen to rely on technological advances to reduce production expenses in their company. Based in Givors, Famer is an SME which employs 250 employees. Its turnover is estimated at 50 million euros and its level of investment dedicated to equipment renewal far exceeds the average for SMEs. This type of management allows the company to stay at the cutting edge of technology. The statements of Jean-Philippe Termoz, the CEO of this structure, leave no room for doubt. “To be competitive in France,” he explains, “fixed costs must be the lowest.” Its export turnover, estimated at 70% of the company’s overall turnover, is concrete proof of its success. The products thus manufactured are intended for large global firms operating in fields as varied as the automobile industry, industrial engine manufacturers and the transmission industry.

Some consider process improvement and better resource management to be the basis of cost reduction in business. General Director of Ateliers des Janves, Jean-Michel Lesire presents the outlook for his company for the year 2022. According to him, if the price of parts currently represents 20%, the objective is to drop below 15%. “This is the main position where we can act,” he emphasizes. To achieve this, the company chose to robotize its hammer-mounted manufacturing lines. You should know that the manufacturing of connecting rods used in automobiles represents 60% of their activity. Thanks to robotization, the number of workers has gone from 5 to 1 at certain workstations. Another advantage is that the hot calibration of parts at the end of the cycle is now put online.