SACMI Imola is an international manufacturer of machines and complete plants for Ceramics, Packaging (including Beverage and Closures&Containers), Food industries, and Automation. Thanks to the innovative technologies, SACMI Imola, located in Italy, has become a worldwide leader with more than 80 branches, 27 production plants, and 4200 employees.
Fifteen years ago, the increasing outsourcing and the great product range led the company to set up a dedicated team to the machines industrialization. Today the industrialization team, that was born for conducting estimates analysis for the whole Group, consists of 6 engineers with strong skills in cost estimations.
Before using LeanCOST, the product cost estimation process was complex and time-consuming since it was carried out by spreadsheets or customized systems. Hence, the company was looking for a software tool that would increase the productivity of the industrialization team, by improving timing and consistency of the stored data, and, finally, that would expand the product cost estimation to the other worldwide company business and branches. Even other business areas wanted to achieve high performances by deploying a tool that would support simulation, analysis, and cost optimization:
- Technical Department needed to evaluate costs, before prototyping and pre-series production, preventing costly revisions or delays in a new machine release.
- Purchasing Department wanted to simulate different cost scenarios, in order to select the best suppliers with which to build a value-added relationship.
SACMI’s competencies on all manufacturing technologies (turning, milling, drilling, grinding, cutting, carpentry, thermal treatments, and coatings) led Hyperlean to perform optimized LeanCOST’s cost models. LeanCOST has been successfully introduced in the industrialization department that today can automatically calculate the cost from a 3D CAD model both of single components and assemblies. The dedicated interfaces created for technical department enable designers to evaluate, from the earliest design phases, the impact of changes in total cost, and to analyze alternative solutions in real time. In the procurement phase, LeanCOST allows having a high visibility on the cost components and quickly comparing the estimates of suppliers based on updated and objective parameters.
Thanks to the possibility to share detailed and reliable information, some of the SACMI Group’s strategic suppliers adopted the software to have a more constructive dialogue with their customers and to understand any gaps between supply and demand. Finally, LeanCOST can easily be connected with enterprise systems (PLM and ERP), facilitating the exchange of information. The Sacmi Group achieved relevant benefits:
- Analytical quotes with accuracy ± 15% (automatic estimation);
- Reduction on time estimation – 50% (compared to the use of standard estimation tools);
- More fact-based negotiation with suppliers;
- Greater speed in recovering the cost data by integrating LeanCOST with enterprise ERP and PLM systems.