Velux is well known for providing roof windows with high product quality and weather resistance. An important component in the window is the flashing that sits between the window and roof. The flashing must – throughout the entire lifetime of the window and under strong influence from sunlight and temperature fluctuations – ensure that wind and rain is kept outside.
Velux has a wide range of flashings, which are adapted to different window sizes, roof types and building standards. With an increase in sales on a global market, Velux now needs to produce several versions in varying quantities. The flashings are manufactured in a variety of sheet metal working processes and the requirement for flexibility therefore gives an expanding range of machines and tools in the existing production setup.
Worm Development has, in close cooperation with Velux’s own production and development staff, helped to identify opportunities to streamline the use of tools in order to make the production more flexible and reduce change over times. By looking at the variance across the product range and the different production lines, Worm Development has created an overview that provides Velux with a better basis for making decisions about consolidation of tools and rationalization potentials.
Out of a variety of potentials Velux has now selected three specific improvement projects with a sound business case that provides savings in direct costs in addition to an improved flexibility with fewer tools and machines.
It has laid the foundation for development of the future product program, for a global market where price, customization and shorter lead times are of the essence.
With a competent, structured and informal approach, and with an astonishing speed, the consultants from Worm Development have acquired sufficient knowledge about our products and challenges to help us think in new ways.
By analysing the way we create variation across our product range, we have identified a number of new optimization potentials with a good business case, and they will be implemented in future product launches.