Case study 6

Flexibility by means of standardisation


Starting situation

One of our customers uses many different packaging designs and sizes. In a weather-dependent and extremely volatile sector, the required quantities of the individual packaging vary significantly.


Delicacy manufacturer


Less investment – more flexibility


To achieve as much flexibility as possible and reduce the investment volume at the same time.


The product portfolio was analysed and divided into different size classes. For these size classes, the necessary quantities were examined and also the required number of cavities (uses). Optimum system and tool sizes were defined from this analysis. In order to keep production costs down, relatively large systems (= high output quantity) were designed. The wide variety was depicted in the systems using changeable insert groups for tools and automation.


All of the required variants can alternately produced with a relatively small number of standardised systems and tools.

Customer benefit

It is possible to manufacture the item cost-effectively due to the size of the systems. Because of the standardisation of the tools and systems, we are extremely flexible and can therefore react to the severe fluctuations in customer quantity requirements. This also gives us a certain amount of fail-safety, since production can continue with another system if a major problem occurs. The use of insert groups means that the investments in tools and automation are significantly lower.


Improvement to

  • Efficiency
  • Flexibility