Turnkey commissioning of a crankshaft manufacturing line in Vietnam

Scope

As part of a major industry project, the FFG Group (MAG IAS GmbH) commissioned Faircom to implement a turnkey crankshaft production line for the first Vietnamese automotive manufacturer Vinfast. Faircom took overall responsibility for the project, from strategic consultation and technical planning through to implementation and commissioning.

A key part of the project was assisting Purchasing in selecting and commissioning suitable suppliers. Faircom was also responsible for planning installation, commissioning and optimising the entire line. Quality inspections were arranged and conducted and a comprehensive time schedule drawn up and continually monitored. Supplier management involved up to ten companies and their services needed to be coordinated precisely on a technical level and in accordance with deadlines.

Faircom also planned the entire logistics, especially international shipping of the equipment and machines from Germany to Vietnam. Construction site management and reporting to management, the Executive Board, on an ongoing basis also fell within Faircom’s remit.

The final step comprised organising and providing support for the production launch of crankshaft manufacture for series engines destined for the Asian market.

Project details

Sector: Automotive (combustion engines)/plant and mechanical engineering

Client: FFG Group (MAG IAS GmbH)

Location: Esslingen/Fils, Germany (50%) – 2018 / Hai Phong, Vietnam (50 %) – 2019

Undertaken by: Waldemar Graf, Rolf Thelen, Tri Vu Quoc

Time period: 2018–2019

Vinfast ordered a turnkey crankshaft production line from the FFG Group (MAG IAS GmbH). The initial situation was extremely challenging since the planning work was started virtually from scratch. Faircom was tasked with undertaking the entire planning for the project with the clear goal of attaining all technical, scheduling and quality goals despite the project’s high complexity and tight deadlines.

Faircom’s objective for the project was to fully plan and implement crankshaft production in the role of general contractor. This included managing all suppliers, commissioning the line on schedule in Vietnam and ensuring compliance with quality specifications and a smooth production launch.

The project period was extremely tight, a third shorter compared to similar projects. This ambitious time line imposed extremely strict requirements on planning, coordination and implementation. Moreover, there was the added complexity of managing up to ten different suppliers whose services needed to be coordinated with one another so that the entire line would function correctly.

Despite all the challenges, Faircom managed to put the crankshaft production line into operation by the deadline. All quality specifications were met and the production launch went as planned. The line was successfully handed over to the operator without any delays.

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