What were the worst mistakes made by Globestelle during the production development process ? CASE 15 Case
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What were the worst mistakes made by Globestelle during the production development process ?
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CASE 15 Case date 2001 The Reltex Project Nigel Slack Globestelle is the world's largest precision diecasting company. It is a global enter- prise, with 20 plants in 15 countries, providing a diecasting service, from designing and prototyping to full-scale production runs, in specialist equipment. Diecasting is a process where molten metal is injected into a die which forms it into its required shape after which it is rapidly cooled. The process allows very com- plex and high-precision components of a range of sizes (but particularly small) to be reproduced consistently in large volumes. Often, diecasting can replace conven- tional metal forming processes such as machining, turning, moulding, pressing and fabricating. Examples are car lock mechanisms and connectors for the automotive industry, battery shields in mobile phones and payphone push-buttons. Globestelle also has a large plastics injection moulding operation which produces similar results using plastic material. The project starts In November 1998, Globestelle's sales office in Cologne received an order from Reltex, a nearby automotive components manufacturer. Reltex required 'Xway mag- nesium connectors' as part of its contract with another automotive supplier, AGT, a division of a major vehicle manufacturer. The Xway connector project was the largest single project Reltex had ever undertaken. Furthermore, it was both outside its core business and far more complex than anything it had produced before. It was also unfamiliar with the diecasting process, hence the involvement of a specialist supplier. The Programme Manager for Reltex explained: 'This was a huge project for us. Previously the biggest project we had handled was worth around €18 million. This one was €100 million of which the Xway connector was around €60 million. It was also the first time our customer, AGT, had gone outside its own vertical structure for a product like this. I guess we didn't really understand the implications of all this, especially as it impacted on supplier development.' The development and manufacture of the Xway connectors (which even for Globestelle, was technically complex) was due to take place at Globestelle's Stuttgart plant. A consultant, Franc Warde, was brought in to head the project in November 1998. By December, a prototype die had been developed to be used in a trial run. CASE 15 Case date 2001 The Reltex Project Nigel Slack Globestelle is the world's largest precision diecasting company. It is a global enter- prise, with 20 plants in 15 countries, providing a diecasting service, from designing and prototyping to full-scale production runs, in specialist equipment. Diecasting is a process where molten metal is injected into a die which forms it into its required shape after which it is rapidly cooled. The process allows very com- plex and high-precision components of a range of sizes (but particularly small) to be reproduced consistently in large volumes. Often, diecasting can replace conven- tional metal forming processes such as machining, turning, moulding, pressing and fabricating. Examples are car lock mechanisms and connectors for the automotive industry, battery shields in mobile phones and payphone push-buttons. Globestelle also has a large plastics injection moulding operation which produces similar results using plastic material. The project starts In November 1998, Globestelle's sales office in Cologne received an order from Reltex, a nearby automotive components manufacturer. Reltex required 'Xway mag- nesium connectors' as part of its contract with another automotive supplier, AGT, a division of a major vehicle manufacturer. The Xway connector project was the largest single project Reltex had ever undertaken. Furthermore, it was both outside its core business and far more complex than anything it had produced before. It was also unfamiliar with the diecasting process, hence the involvement of a specialist supplier. The Programme Manager for Reltex explained: 'This was a huge project for us. Previously the biggest project we had handled was worth around €18 million. This one was €100 million of which the Xway connector was around €60 million. It was also the first time our customer, AGT, had gone outside its own vertical structure for a product like this. I guess we didn't really understand the implications of all this, especially as it impacted on supplier development.' The development and manufacture of the Xway connectors (which even for Globestelle, was technically complex) was due to take place at Globestelle's Stuttgart plant. A consultant, Franc Warde, was brought in to head the project in November 1998. By December, a prototype die had been developed to be used in a trial run.
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