cases

Best Practices

Real projects. Real figures.

No glossy brochures, just tangible results from real customer projects. From the initial enquiry to the component in stock. Here you can see the end result.

Best Practices

Real projects. Real figures.

No glossy brochures, just tangible results from real customer projects. From the initial enquiry to the component in stock. Here you can see the end result.

Refrigeration and air-conditioning technology

Case Study: Sustainable Cost Reduction and Supplier Diversification in Refrigeration and Air-Conditioning Technology

Initial situation

A leading company in the refrigeration and air-conditioning sector faced a critical challenge in its procurement function: for several components critical to the system and safety, there was a heavy reliance on just a single supplier in each case. This one-sided supplier structure led to prices being raised continuously over a number of years – whilst the customer’s bargaining power remained limited.

Challenge

The greatest challenge lay in identifying alternatives for highly complex and safety-critical components. In addition to technical requirements, it was also necessary to ensure compliance with certifications and quality standards, as well as long-term supply security.

Our approach

As procurement consultants, we have implemented a structured optimisation programme:

Results

Significant improvements have been achieved through the systematic reorganisation of the supplier portfolio:

Conclusion

This case study demonstrates how strategic procurement and targeted supplier development can not only deliver significant cost savings but also reduce structural risks in the long term. A diversified supplier base is a crucial competitive advantage, particularly in technically demanding sectors such as refrigeration and air-conditioning technology.

Waste management technology

Case Study: Quality optimisation and sustainable cost reduction through Exxcility’s comprehensive supply chain solution for waste and recycling bins

Initial situation

A leading company in the waste and recycling bin sector faced the challenge of optimising its production capacity for new client projects.

Challenge

Previous attempts to secure an additional source of supply for the welded assemblies in question were less successful. The current partner experienced significant quality and delivery issues, making it difficult to guarantee long-term supply security for its customers.

Our approach

As a systems provider covering the entire supply chain, we took care of the problem for the customer.

Results

This approach helped to minimise the challenges faced by the customer, enabling them to plan their production capacity for new projects whilst having a partner at their side who ensured product quality and on-time delivery.

Conclusion

The case study demonstrates how, through collaborative partnership and Exxcility’s targeted management and control of the supply chain, the client is able to free up production capacity for new client projects whilst at the same time ensuring the worry-free, high-quality and on-time delivery of existing products. In addition, the client was also able to optimise its purchase prices by outsourcing the process to Exxcility.

Lichttechnik

Case Study: Kostenreduktion und nachhaltige Bauteiloptimierung in der Lichttechnik

Initial situation

A company specialising in lighting and lighting technology faced the challenge of designing a rapidly growing sheet metal component in a way that was both more cost-effective and more sustainable. As production volumes rose, increasing attention was paid to the cost structure, material usage and environmental considerations.

Challenge

The aim was to find a solution that would not only reduce the unit price but also incorporate more sustainable materials or manufacturing approaches – without compromising on quality, functionality or scalability. At the same time, the aim was to systematically tap into the international procurement market in order to identify new opportunities.

Our approach

As procurement consultants, we have implemented a comprehensive analysis and optimisation programme:

Results

Thanks to our structured approach, we were able to deliver a number of benefits:

Conclusion

The case study illustrates that strategic procurement goes far beyond mere cost optimisation. By combining market transparency, an understanding of technology and close collaboration with the development team, it has been possible to achieve both economic and sustainable improvements – a clear competitive advantage in an innovation-driven industry.

Barriers and barriers systems

Case Study: Sustainable Quality Improvement and Supplier Development in Barrier Technology

Initial situation

A company specialising in barrier technology sourced reflectors and stickers from a supplier in China and found itself facing significant quality issues. The poor product quality led to high rejection rates during incoming goods inspection, as well as rising internal process costs.

Challenge

In addition to stabilising quality in the short term, the key challenge was to address the root causes throughout the supply chain in a sustainable manner. Particularly in adhesive applications, the materials, process parameters and manufacturing conditions had to be precisely coordinated.

Our approach

As quality consultants, we have implemented a comprehensive package of measures:

Results

Thanks to close cooperation and the consistent implementation of the measures, sustainable improvements have been achieved:

Conclusion

This case study demonstrates how even complex quality issues can be resolved in a sustainable manner through targeted supplier development, technical expertise and an international presence. Particularly in global supply chains, ongoing on-site support is a key factor in ensuring stable processes and high product quality.

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Commercial vehicle manufacturing

#Consultancy · #Procurement · #Quality

~41%

Cost savings

Two welding assemblies newly qualified for trailer bodywork

A commercial vehicle manufacturer enquired about a complex welded assembly. Within two weeks, we had put forward a comprehensive quotation in collaboration with our partner factory in India, including interim storage in Altenberge and just-in-time (JIT) delivery. Following a detailed process analysis, we relocated the welding and coating operations to Germany, saving a further €100 per unit. We achieved the same result with a second assembly for the rear section. Incidentally, quality improved as a result of a better coating.

Commercial vehicle manufacturing

#Consultancy · #Procurement · #Quality

~15%

below the previous costs

Welded assemblies and stamped and bent components for a new generation of chassis

For the new generation of chassis, we put together a comprehensive quotation at short notice, in collaboration with our partner factory in India and other network partners in India and China, including interim storage in Altenberge and just-in-time (JIT) delivery. The price was 15 per cent lower than the costs the customer had previously enquired about. We ordered the initial samples, carried out quality assurance and prepared the initial sampling documentation. This enables the customer to manufacture at optimal costs from the start of series production whilst simultaneously reducing their supply chain risk.

Mechanical engineering · Forged parts

#Consultancy · #Procurement · #Quality

141.000 €

Annual savings

New drawing documents for a valve disc, produced from the sample

The drawing for a widely used forged component dated from 1992 and no longer reflected the current situation. As production volumes had risen sharply and all parts were sourced from a single supplier, a second supplier was to be brought on board. Using 3D scanning, spectral analysis and Brinell hardness testing, we created an up-to-date drawing based on several samples, in consultation with the development team. Production takes place at our partner’s facility in China, with our SQE ensuring quality on site. We now supply 5,000 valve discs per month and save the customer €141,000 per year.

Vehicle construction

#Consultancy · #Procurement · #Quality

3.000 €

Savings per vehicle

An international supplier portfolio for a new vehicle

A vehicle manufacturer launched a new product, driven largely by external procurement, with production volumes still uncertain during the ramp-up phase. Together, we defined the objective: to build an international supplier portfolio and reduce costs without becoming entirely dependent on non-European sources. Over an 18-month period, we reduced costs across many product groups – by an average of €3,000 per vehicle – and brought on board around a dozen new suppliers. The product is now more competitive in the market, and the savings will amount to a seven-figure sum over the years.

Large-scale casting

#Consultancy · #Procurement · #Quality

8%

less weight

A new approach to cast components, using our own 3D models

A high-volume manufacturer wanted to relocate around 20 per cent of its annual requirement for a complex cast component from Poland to India, but had neither a supplier nor a network there. We examined the component, created our own 3D models and optimised its design and weight. The customer’s development team approved a proposal that reduced the weight by 8 per cent. On this basis, we put out a tender to pre-qualified suppliers. Our team at Exxcility India provided on-site support throughout the first-article testing and series production ramp-up. The result: savings in the high six-figure range per year and a significantly more resilient operational setup.

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