From prototype production line to efficiency: The transformation at VIA Optronics

VIA Optronics develops interactive display systems (IDS). Photo: VIA Optronics

VIA Optronics GmbH is a renowned provider in the field of interactive display solutions with a broad portfolio that includes technologies for optical bonding, copper-based metal mesh touch sensors and customized interactive display systems. Over the course of 2019, our consulting company provided VIA Optronics with comprehensive support in the implementation of a new production line and the introduction of the first Industry 4.0 solutions at the Nuremberg site.

The consulting mandate focused on the production of 42-inch touch displays, which are primarily used for air traffic control systems. The challenge was to scale production efficiently during the ramp-up phase. The initial situation was characterized by a prototype production line, low output and a high susceptibility to errors in the production processes. There was also a lack of systematic collection of production data.

These challenges resulted in several specific goals for the project. These included the complete redesign of the production layout, the integration of a fully automated production line in a limited space and the significant increase in output to the defined target number of units. The aim was also to implement a scanning system for data collection and real-time data monitoring. Continuous and sustainable improvements were to be achieved through lean processes, data-based price calculation and error analysis and elimination.

By applying Lean management principles and Industry 4.0 strategies, the target number of units was achieved and the production process was significantly optimized. In addition, product quality was improved, processes standardized and production accelerated. These optimizations led to concrete project inquiries from international companies that considered working with VIA Optronics.

The next steps for VIA Optronics are the international implementation of sustainable store floor management and the completion of scanning processes for all projects.

This is what VIA Optronics says about the support from the Lean Group:

Dr. Farouk Zabel, COO EMEA. Photo: VIA Optronics

"Together with the consultants from the Lean Group, we succeeded in standardizing the production of 42-inch touch displays and digitalizing the production processes. The consultants' strategic know-how helped us to reorganize the production line and transfer these structures to other projects. They raised VIA Optronics to the first Industry 4.0 level within a short space of time. For us, this is an important step towards a stable future."