Manufacturing Transformation for Reflexallen
Outsourcing a Complex Production Line
When Maehler & Kaege decided to outsource their production, they needed a partner capable of handling a variety of some 100 different products while maintaining a total annual volume of 15 million parts. The challenge was significant: adapting mass manufacturing techniques to smaller batch sizes, ensuring quick changeovers, and implementing efficient production flows for high-mix, high-volume manufacturing.
At Gebrema, we saw an opportunity to optimise their production, balancing efficiency with flexibility to meet their unique needs.
Innovating Production for Efficiency
To tackle the complexity of their product range, we:
Redesigned production flows by grouping parts into families, allowing for fast machine changeovers and efficient scheduling.
Invested in new machines capable of handling smaller batch sizes while maintaining high precision and repeatability.
Developed a fully integrated machining and assembly process, where raw brass enters our rotary transfer machines and exits as fully assembled asymmetric parts with screws, eliminating secondary operations and thereby increasing efficiency.
This approach allowed us to deliver a reliable, cost-effective, and scalable solution tailored to their needs.
Long-Term Reliability Through Business Transitions
Even as Maehler & Kaege transitioned to Reflexallen S.p.A, experiencing ownership changes, shifts in assembly line locations, and new procurement teams, Gebrema remained a constant and trusted supplier. Our deep understanding of their product requirements and industry needs ensured a seamless supply chain, even during the most challenging transitions.
Beyond Machining: A Full-Service Solution
Our commitment to Reflexallen extended beyond manufacturing. We also organised surface treatments through our trusted network, ensuring that their parts met the right quality and pricing standards—eliminating the need for additional supplier management on their end.
Why Customers Trust Gebrema
Seamless Ramp-Up Process – Efficient solutions tailored to complex manufacturing needs.
Decades of Expertise – Precision manufacturing trusted since 1950.
Unmatched Service Quality – A long-term partner that adapts to business changes and challenges.
Looking for a manufacturing partner who can handle complexity while ensuring reliability? Let’s talk!