Der Kostendruck auf Deutsche Automobilzulieferer
Deutsche Automobilzulieferer face enormous cost pressures: OEMs demand 3–5% annual price reductions as standard, impose 10–20% cost targets during model changes, and conduct independent should-cost analyses. Operating margins have compressed from 8–12% to 4–6%. Energy costs run 40–60% above the EU average, while the shift to electric mobility requires costly new technology investment on shrinking margins.
Wertanalyse vs. Klassische Kostensenkung
Traditional cost reduction enforces price cuts without technical changes, achieving only 5–10% savings that strain supplier relationships and can harm quality. Value analysis (Wertanalyse) systematically analyses functions and develops optimised solutions, achieving 15–35% reductions that are structurally sustainable and often improve quality. The key distinction: classical cost reduction redistributes the pie; value analysis shrinks it while preserving function.
Welche Bauteile Eignen Sich für Wertanalyse?
- High-value machined parts (>€50): transmission housings, suspension components — 15–35% savings potential
- High-volume parts (>50,000/year): brackets, clips — small per-unit savings multiply significantly at scale
- Over-dimensioned legacy parts: safety factors >3.0, unvalidated tight tolerances — 25–45% savings potential
- Multi-part assemblies: part consolidation yields 20–40% savings plus assembly simplification
- Components with quality issues: redesign for manufacturability yields 18–35% savings with 40–70% quality improvement
Wie Viel Einsparpotenzial ist Realistisch?
CNC-machined parts: 22–38%. Castings: 25–42%. Sheet metal: 18–35%. Multi-part assemblies: 28–45%. A first value analysis on unoptimised parts typically yields 20–38%, with payback in 8–24 months at automotive volumes above 20,000 units per year.
Der Ablauf eines Wertanalyse-Projekts
Phase 1 — Preparation (2–3 weeks): component selection, team formation, cost data collection, and functional analysis preparation. Phase 2 — Two-day workshop: functional analysis, brainstorming 30–80 alternative ideas, concept evaluation, and business case development. Phase 3 — Implementation (3–12 months): detailed design, prototyping, tooling, and PPAP. Phase 4 — Production launch with savings tracking. Typical result: 5–10 implementable concepts delivering 20–35% cost reduction.
