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These customers trust us

Cases and Customers:

As a full service partner, we have been active across industries for customers of very different sizes, sometimes for many years. These are some of them.

How our customers

benefit

Our customers’ implemented projects

In all projects, we achieve benefits in terms of costs, processes and quality for our customers. Here, our customers benefit from our view “from the outside” and our knowledge-transfer between industry standards, which we can turn into a profitable advantage for them.

Case: Door-opening system (industry: Mobility)

  • Challenge
For a door-opening system in a public transport system, a customer was supplied with individual cast components for many years. After delivery, the individual components were assembled and tested by the company itself, in very slow and labour-intensive steps.
  • Solution
The outsourcing of assembly building to novia optimised the process and simultaneously achieved cost savings. For this, the assembly and quality testing using the most up-to-date testing technology was defined on site, together with the customer. Complete, quality-tested assemblies are now delivered instead, and they can be installed directly.
  • Result
  • Part price optimised by ~15%+
  • Significant reduction in assembly complexity
  • Assembly process shortened considerably

Case: Modular bench seat for passenger transport (industry: Mobility)

  • Challenge
A globally leading OEM in passenger transport had to cope with complexity and a high number of variants in the manufacture of bench seats. This resulted in high costs for the complicated, project-specific procurement of individual components from numerous external partners. The process was time-intensive and error-prone and, at the same time, had a very high working capital requirement.
  • Solution
By developing a modular bench seat with a great variety of versions in terms of number of places, materials, upholstery, lighting, etc., we have reduced the complexity and thereby the procurement overhead. novia received the order to manufacture the bench seats ready to install, reducing the number of production processes for our customer. By implementing a vendor-managed inventory programme at novia – with flexible call-offs up to 3x per week – the inventories were also optimised.
  • Result
  • Part price optimised by ~20%+
  • Ready-to-install delivery to the assembly line
  • Significant stock reduction through vendor-managed inventory

Case: Drive casing for operating table (Industry: Medical technology)

  • Challenge
For a drive casing for operating tables, certain areas must be electrically conductive. The customer’s concept was to mask the corresponding areas and anodise the drive casing before removing the masking wax.
  • Solution
To save time and money, novia adapted the process: The complete drive casing is anodised, and then the anodising is removed by laser from the areas, which have to be electrically conductive.
  • Result
  • 500+ hours saved in personnel costs (per year)
  • Automated solution for de-anodising
  • (Manual) masking and de-masking unnecessary

Case: Optimisation of de-anodising (Industry: Medical technology)

  • Challenge
For drive casings for operating tables, certain areas must be electrically conductive in order to fulfil the regulations and standards for static discharge and grounding of medtech assemblies. The original approach had planned for the red areas to be masked using wax and plugs and for the drive casing to be anodised. The masking would then be removed laboriously by hand.
  • Solution
We anodise the complete drive casing and use a laser to remove the anodising from the areas marked red.
  • Result
  • 500+ hours saved in personnel costs (per year)
  • Automated solution for de-anodising
  • (Manual) masking and de-masking became unnecessary

Case: Optimisation of manufacturing process (Industry: Construction industry)

  • Challenge

The manufacturing costs were to be reduced for a powder-coated, CNC-machined pressure-cast part made of aluminium. It was essential for the customer to meet a defined target price for the part and for the new generation of the machine to become more cost-efficient than its predecessor.

The customer engineering on the drawing defines the manufacturing process as pressure casting, coating, and then milling. This involves costly manual masking of milled functional surfaces.

  • Solution
Using a milling jig specifically developed for the purpose, the parts are machined after powder coating, and filings are removed in such a way that the coated surface of the parts is not damaged. The laborious masking before powder coating is therefore no longer necessary. This hugely reduces the unit price.
  • Result
  • 40+ % saving in the unit price

Case: Costs drop through additional upstream manufacturing process (Industry: Medical technology)

  • Challenge

An extremely complex milled part is created exclusively by CNC-machining. This removes 10 kg of filings. This process causes very long manufacturing times of approx. 4 hours per part. The high-strength aluminium part has approx. 400 drawing dimensions, of which 80 are defined as functionally critical.

By transferring the task to the novia Group, the costs were reduced by a factor of 4. However, we see even further potential savings for the customer.

  • Solution
As an additional manufacturing process, we propose a drop-forged blank with tool costs that will cut down the CNC-machining time by slightly more than 2 hours overall. We design the blank so that it is milled completely. We thereby save the customer the trouble of modifying their current drawing, avoiding laborious approval and certification processes.
  • Result
  • Cost saving of 30% compared with the original process
  • Break-even of the tools after the first half-batch

Cost-effective manufacturing partners paired with the intelligent selection of the optimum process and technical optimisation of your products – there are numerous approaches to reducing the total cost of ownership.

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