Simplify everything!

Simplify your products!

Simplifiy your customers’ life!

Simplify your offer!

Increase your value!

STUDY CASES

These examples (mostly unnamed) illustrate some of the concrete contexts and contributions of the missions we run.
They will be updated regularly.

EMERGENCY REDESIGN TO COST OF “MASS PRODUCTION” PRODUCT RANGES FOR THE BUILDING INDUSTRY

« We jumped out of the plane, now we have to sew the parachute quickly! »

So said the plant manager of a major French building equipment group.
The sharp drop in sales due to an ageing image and costs that were not competitive enough had led to the company taking the bull by the horns : the image and the catalogue were to be redesigned and sales prices were already being drastically reduced… at the cost of heavy financial losses!
It was urgent to radically reduce costs, without sacrificing Quality…

The Redesign to Cost of the two major product ranges was launched:
– The Functional Analysis identified the key requirements and the right needs,
– The Flash Benchmarking highlighted the significant differences in solutions and costs with the competition,
– The Value Analysis quickly listed the major potential savings: in total, almost 50% of questionable costs, including possible Qwick Wins
– The research and evaluation of solutions finally identified the real gains and their precise implementation programme:
the almost immediate 6% Quick Wins would become 25% real gains on both ranges, with deeper design and process improvements.

In less than 4 months, the Redesign to Cost had set the course for the expected profitability.

 

DESIGN TO COST OF A GAS CONDENSING BOILER

François VUILLAUME – R&D Director – ELM LEBLANC – Groupe BOSCH

“The problem was to reduce the cost of the products but in a context of strong constraints: as all the components are already defined, we tend to think that there is only one possible solution… and the work carried out allows us to demonstrate the opposite!
The technology is that of the condensing boilers – there are the traditional atmospheric burners, a technology that comes from the natural draught wood-burning fireplace – and for energy saving reasons we can now use this condensing technology which allows the flue gases to be cooled more and more energy to be withdrawn for the same amount of gas spent…

The advantage is that it is very direct! The method you propose is very flexible, very light, very reactive and can be integrated into the heavy procedures of any company. Companies like ours, and I believe others, have very efficient, very well established procedures, but which are in fact quite cumbersome, and you bring in a small method which acts very quickly and very locally, without disrupting the global procedures and which is compatible with them, and which makes it possible, for a certain period of time, to accelerate the functioning of normal procedures.

The gains are amazing! You are always amazed at the potential gains that can be made by putting everything back together.
It’s a method which clearly needs to be renewed, and finally, the interest of this work – because there is a training aspect – is that we integrate a way of doing things which we can develop internally. But in any case, it is still necessary to have an external incentive.”

DESIGN TO COST AND VALUE  OF AN AIRCRAFT ENGINE COMPOSITE PLUG

Yann RICHARD – ARCOCE Program Ditrector – SNECMA PROPULSION SOLIDE – SAFRAN Group

“We are on an R&T programme. ARCOCE stands for “Arrière COrps Composite CEramique”; it is a programme which aims to develop a rear body part for civil aeronautics: the CFM56 engines and their replacement, the LeapX, are the engines of single-aisle aircraft. The A320 family for Airbus and the 737 family for Boeing will need new, “greener” engines that consume less and pollute less, in terms of NOX or CO2, but also in terms of acoustic emissions. The aim of this programme is to introduce a plug based on CMC, a ceramic matrix composite, which can withstand high temperatures to gain weight for civil aircraft.

With Arolys, we began a Functional Analysis – we came back to the real need of the part – then to define the Just Necessary in terms of definition/design. This phase, for our very upstream R&T programme, was very rich because it enabled us to highlight solutions that would have been overlooked. The purpose of phase 2 was to sort out the most convincing solutions.

The strong points of the Arolys approach were mainly to push people to think in a new context and to shed a great deal of light on the cost vision and cost levers to reduce the final production cost, which at t0 was much higher than the target set at the end of the programme.
In the end, we have a strong overall impression of efficiency: when we look back on what we did, we see very few wasted hours, which is a fear we have when we start the process; about 8 one-day sessions each, and in the end everything bore fruit, whether it was phase 1, creative, or phase 2, sorting. A very positive assessment of the process.

Today we can see the results of this work in our design and in our production range and so, to do it again: yes, and for a future programme of the scale of ARCOCE, we will do it again: yes.”

Peggy DEUSCHT – Site Director Centre of Excellence France – CONDUCTIX

” Arolys’ support was a real success because the approach is extremely pragmatic and concrete. It is a field support that is as close as possible to the teams, which gives a rhythm and a permanent adjustment to our needs. Beyond the results on the equipment itself, this approach has brought the teams closer together… it’s almost like team building! “

Silvere JAMAIN – Product Line Manager – SOMFY

” Great animation, bravo to the animator because it is indeed difficult to align the minds to the guideline.
To be repeated on projects that require it.. “

François CORSO – Design Office Manager – CONDUCTIX

” We appreciated the undeniable methodological contribution on the functional definition and the absolute necessity to judge the levels of flexibilities to define the right need.
The cost breakdown method is simple and pragmatic, which makes it possible to challenge the definition of the product and to imagine new concepts to achieve the cost reduction objectives already in this phase.
A great dynamic was created between the teams during this analysis, which continued during the implementation of the project. “

Pierre BRION – Head of Engines division – SOMFY

” The method is simple and the approach is based on a lot of pragmatism and common sense. Moreover, it allows the experts present to collaborate and to reach a consensus. I have rarely seen an approach of this type bring us to this level of result in such a short time. Bravo AROLYS!”

Denis GALHAUT – Design Office – CONDUCTIX

” A “salutary” performance that highlighted a daily reality. “

Benjamin STALDER – Project Manager – CONDUCTIX

” I particularly appreciated this approach which took me out of my purely technical vision. It is global and efficient. It gives a lot of clarity to the management (and obviously to ourselves). “

Dominique WEGRICH – Industrialisation Technician – PAUL HARTMANN

” It was a complicated process given the company’s requirements, well done for the adaptation and analysis. “

Xavier GOUSSET – Méthodes – ALDES

” The fact of having an external facilitator (Arolys) obliges us to reformulate our needs without taboos. This is to ensure that they are understood by the whole project group, including Arolys (role of candide). As Arolys has a timetable to respect, it forces us to make quick decisions to enable the synthesis at the end of the process. “

Nicolas TORTIGUE – Purchasing Manager – LAPEYRE

” Good service. Listening to the participants. “

Dominique WEGRICH – Industrialisation Technician – PAUL HARTMANN

” Complicated health situation, we still managed to bring up the levers for improvement. Thanks to you.    “

François VUILLAUME – R&D director – ELM LEBLANC (BOSCH group)

” A method that can provide the little extra needed for a successful project. “

Olivier FREZET – Sales managers – CONDUCTIX

” The Design to Cost approach proposed by Arolys is a very good application of the precept “To decide is to choose, to choose is to give up”.
Philipe not only provided us with a methodology, but above all helped us to take a step back and make natural decisions.
This exercise should therefore be considered as much a technical process as a change management process. “

Mickaël REQUIN – Project Manager – SCHNEIDER ELECTRIC

” The training is very useful and opens the mind to the design to cost approach upstream and downstream of projects. “

Vladimír – Material productivity manager – SCHNEIDER ELECTRIC

Traduit de l’anglais

” It is also good to see the reaction of other participants or other ideas shared during our meeting. “

Jonas JUNKER BENGTSEN – Process specialist – VEOLIA KRÜGER

Traduit de l’angalis

” Arolys was very helpful when we didn’t know where to go or how to proceed. “

Anne-Laure THIEBAUT – Controlling Management – PAUL HARTMANN

” The Arolys team was able to grasp the complexity of the subject while applying a simple, structured approach that revealed the areas for improvement! “

Guillaume CHAMPON – Process manager – FRESENIUS KABI

” A nice approach of the cost reduction, very complete and realistic “

Frédéric MARTIN – Plant Manager – LAPEYRE

” Effective and participatory method, sometimes challenging received ideas. “

Pascal FRANCOIS – Methods Engineer – ALDES

” A rigorous approach with a mastery of animation, relevant conclusions to be put in relation with the industrial context which does not necessarily allow the approach to be completely successful. “

Maud OLLER – Chef de projets – ALDES

” The intervention of an external person is positive because it removes internal tensions and people are more available. “

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