-1-STR-0211-90099-01-34.pptReductionoffixedcostsatTDW–analysisandconcept–Projectproposal–SAIAutomotive,TriangelerDämmstoffwerkGmbH(TDW)Sassenburg,January8,1999RolandBerger&PartnerGmbH–InternationalManagementConsultantsBarcelona–Beijing–Berlin–Brussels–Bucharest–Budapest–BuenosAires–Delhi–Düsseldorf–Frankfurt–HamburgHelsinki–HongKong–Kiev–KualaLumpur–Lisbon–London–Madrid–Milan–Moscow–Munich–NewYork–ParisPrague–Riga–Rome–SãoPaulo–Shanghai–Stockholm–Stuttgart–TelAviv–Tokyo–Vienna–Zurich-2-STR-0211-90099-01-34.pptContentPageA.FixedcostsofthetextiledivisionmustbereducedbyatleastDM5.6mill.–anambitioustarget3B.Theproposedprojectconsistsofthreemoduleswhichwillrapidlyreducethegap8Appendix1:References13Appendix2:Consultant´sprofiles15Thisdocumentwascreatedfortheexclusiveuseofourclients.Itisnotcompleteunlesssupportedbytheunderlyingdetailedanalysesandoralpresentation.ItmustnotbepassedontothirdpartiesexceptwiththeexplicitpriorconsentofRolandBerger&Partners.-3-STR-0211-90099-01-34.pptA.FixedcostsofthetextiledivisionwillbereducedbyatleastDM5.6mill.–anambitioustarget-4-STR-0211-90099-01-34.pptWithstructuralfixedcostsreductionmeasuresthefixedcostsgapcanbereducedrapidly–processoptimizationwouldsurpassthegoalFixedcostsfor„Textile“1999[DMTSD]Fixedcostsfor„Textile“1999[DMTSD]Realisticcostreductiontargets[DMTSD]1)Realisticcostreductiontargets[DMTSD]1)17,8285,64223,470Budget1999Goal199926.3%26.3%20.0%20.0%PercentoftotalproductionFixedcostsgapFixedcostsgap5,642?SurpassthroughprocessoptimizationmeasuresOffsetthroughstructuralmeasuresFixedcostsgap1)Tobeverifiedanddetailledduringtheproject-5-STR-0211-90099-01-34.pptThreemainquestionsmustbeaskedFixedcosts1998(forecast)[DMTDD]1)24,12826,3341,497709about21,000about3,000Istheallocationtootherassemblylocationscorrect?TotalTDWAllocationothers2)Allocation•VWM•Bruxles•Meerane•BratislavaTotalSassenburgTextileDoorpanelassemblyHowcanfixedcostsfor„Textile“bereducedinordertoreducethefixedcostsratiofrom26.3%to20.0%inthe3rdquarterof1999?Istheallocationto„Textile“and„Doorpanelassembly“correct?1)Assumptions:lineardistribution(December=YTD/11)2)IncludingcommoditiesSource:TDWReportNovember1998-6-STR-0211-90099-01-34.pptThetwodivisionsoftheSassenburgplantareratherdifferentinstructureKeyfigures[DMTSD]TextileTextileDoorpanelassemblyDoorpanelassemblyTotalproduction•Actual199874,73443,142•Budget199989,139(+19%)94,484(+119%)Materialcosts(includingsub-contractors)Budget199939,931(45%ofproduction)79,967(85%ofproduction)Fixedcosts•Actual19981)21,000(28%ofproduction)3,000(7%ofproduction)•Budget199923,470(26.3%ofproduction)3,815(4%ofproduction)•technologyintensiveproduction•highvalueadded(55%)•noproduction,onlyassembly•lowvalueadded(15%)Back-up1)Estimate(totalDM24,128TSDwhichequals20.5%ofproduction)-7-STR-0211-90099-01-34.ppt3,9606,13510,8467826995441,7391,62926,334ThefixedcostsbreakdownshowstheleverstobeanalyzedMajorfixedcosts1998(forecast)[DMTSD]1)2)IndirectpersonelDepre-ciationMaintenance(inhouseandcontractors)WastedisposalForklifterserviceTravelexpensesOthersTotalTDWIndirectpersonnel:Productionrelated:•logistics19•production16•maintenance37•processes&methods3•quality8Non-productionrelated•management2•IT4•personel5•finance17•procurement4Total1151)Assumption:lineardistribution(December=YTD/11)2)Includ...
