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Continental: TaskForce Microcontroller & OEE Improvements
Continental AG
The Challenge
One of Continental's major semiconductor vendors (Renesas) was severely affected by the series of earthquakes in Japan in April and August 2016. WIP-materials and Front-End (FEOL) tools were damaged and buffers emptied, leading to critical production interruptions at Continental's global manufacturing plants and their OEM customers.
Our Solution
We deployed a TaskForce team directly to Japan to assess production scheduling, capacity planning and operational processes at the semiconductor manufacturer. We mapped business processes, identified immediate yield improvements, and executed PDCA cycles to reduce performance fluctuations while implementing additional FEOL tools for bottleneck tool groups.
Our Approach
Deployed 6-person TaskForce team on-site in Japan within 48 hours
Assessed production scheduling and capacity planning processes
Mapped complete business processes and identified bottlenecks
Executed PDCA implementation cycles for tool performance
Implemented additional FEOL tools for bottleneck tool groups
Established KPI monitoring and continuous improvement framework
The Results
Improved wafer mix for optimal production output
Implementation of additional Front-End tools for bottleneck groups
Complete elimination of demand-supply backlog
Improved production planning and scheduling accuracy
Significant reduction of waste and scrap rates
"The KFS GROUP TaskForce team was instrumental in getting our semiconductor supply chain back on track after the earthquake crisis. Their rapid deployment and deep process expertise made the difference."
Elmar D.
CEO, Continental Global Procurement