MATE (Motherson)
Automotive
50% Downtime Reduction at Motherson Automotive
World-Class SMED Implementation for Automotive Excellence
Challenge & Solution
The Challenge
- As a Tier-1 automotive supplier, Motherson needed to meet increasing demands for flexibility and quick response to customer orders. The 30-minute mold change time was limiting their ability to handle multiple products efficiently.
The Solution
- Implementation of Lenzkes MQ100 heavy-duty clamping system with enhanced vertical and horizontal adjustment range, suitable for larger molds and higher tonnage machines. Total deployment of 240 clamps across 30 machines.
Before & After Comparison
Quantified operational improvements
| Metric | Before | After | Improvement |
|---|---|---|---|
| Mold Change Time | 30 minutes | 15 minutes | 50% reduction |
| Daily Changeovers | 3 changes | 3 changes | Same frequency, half the time |
| Annual Downtime | 280 hours | 140 hours | 140 hours saved |
These improvements represent measurable operational enhancements achieved through our solution implementation
Implementation View
Key Results
Measurable improvements achieved through our solutions
10,329
Minutes Saved Yearly
Based on 3 changes per day
172.1
Hours Recovered
21.5 additional production shifts
240
Total Clamps Deployed
Across 30 machines
Solutions & Products Used
Lenzkes Magnetic Quick Clamp
Model: MQ100: 100-088-20
6.0T clamping force with 7-87mm vertical range
Additional Benefits
- Flexible clamping for various back plate thicknesses
- No reduction in machine daylight
- Protection of expensive machine platen threads
- Consistent quality through precise clamping
- Enables smaller batch production
Return on Investment
9 monthsPayback Period