Project · Engineering & Methods
Industrial Methods &
Production Performance
Deployed and structured the manufacturing engineering framework on a production line — from SAP routing setup to MES performance analysis — delivering measurable gains in STD time accuracy and labor cost optimization.
Impact at a glance
Key Numbers
Financial Impact
Labor Cost Saving
(4h × 20 units × €250/h)
Context
Challenges
Challenge 01
SAP introduced in 2022 — routings, operations and STD times needed to be built from scratch with no baseline
Challenge 02
Low STD time accuracy (60%) causing unreliable standard costs and poor production performance visibility
Challenge 03
Operators unfamiliar with MES time tracking — incorrect or missed clock-in/out impacting Run time data quality
Challenge 04
MES bugs generating false Run time data — requiring systematic identification and escalation to dev team
Challenge 05
STD time directly feeds standard product cost — inaccurate times impacting financial reporting and cost control
What I did
Actions Taken
Routing Setup & Operation Definition in SAP
Configured 40+ manufacturing routings in SAP — creating an average of 15 operations per routing with full parameter definition.
Operator Training on MES / MEPOD
Trained 30 operators on MES time tracking and MEPOD — covering STD time concepts, Run time vs STD time logic, correct clock-in/out procedures and time reporting accuracy.
STD Time vs Run Time Analysis — 5 High-Runner Products
Conducted systematic analysis of STD time vs actual Run time across 5 high-runner product lines — identifying the least accurate operations and root causes of deviations.
Field Investigation & Root Cause Resolution
Deployed terrain action plans based on analysis findings — distinguishing between STD time misconfiguration, MES bugs, and operator behavior issues.
Standard Cost Optimization via STD Time Accuracy
Aligned STD times with operational reality — directly improving standard product cost accuracy. Achieved 4h saving per unit on key high-runner products, generating €20K+ monthly saving potential at peak production (20 units/month × €250/h labor rate).
MES Improvement Feedback Loop
Consolidated and escalated MES bugs and enhancement requests to the development team — contributing to continuous system improvement and better data reliability for future analyses.
Outcomes
Results
STD accuracy 60% → 87%
+27 percentage points in under 12 months post SAP go-live
€20K+ monthly saving potential
4h saved per unit × 20 units × €250/h on high-runner product
40+ routings fully configured
600+ operations with times, MIC, components and control keys
30 operators MES-certified
Trained on MEPOD, time tracking and STD time culture
IDLE time <10% all year
Stable utilization rate maintained through continuous monitoring
MES bugs escalated & resolved
Structured feedback loop with dev team improving system reliability
“Built the manufacturing engineering foundation from the ground up — structuring SAP routings, aligning STD times with operational reality, and developing operator MES culture to deliver a 27-point accuracy gain and significant standard cost savings in under one year.”
