Achenbach: From ETO to a Modular System
Modularization has an impact that extends far beyond the product structure itself. The example of Achenbach Buschhütten illustrates how a modular product structure gives rise to a modular system that transforms design, procurement, and manufacturing. Today, more than 90% of filter systems are built using the modular system—with significantly less design effort and shorter procurement times.
Faster design, faster procurement, lower production costs—the impact of Achenbach’s modular system
The VDMA experience-sharing event at Achenbach Buschhütten GmbH & Co. KG featured impressive figures and genuine insights into the transformation of processes for highly customized products. Here, Ralf Neuser not only explains how Achenbach made the leap to a modular system a few years ago with the support of Odego GmbH, but also how the transformation from ETO to CTO has progressed since then. “We were able to see the first results just a few months after the project began,” he reports.
The improvements are quite impressive:
➡️ Over 90% of all filter systems are now built using a modular design
⏱️ This reduces design hours per project by 60%
💸 Order-neutral manufacturing and batch-size procurement are now possible, resulting in significant savings in material and manufacturing costs
📅 Procurement lead times are up to 12 weeks shorter
So much for the results in numbers, but how did the transformation unfold? “As the design department, we also had to start bringing the other divisions on board, and Odego GmbH was a great help to us in that regard,” explains Ralf Neuser. The modular system was gradually implemented in CAD, PLM, and ERP and has brought additional benefits in many areas, such as the integration of the company’s own cloud solution, Optilink, and spare parts management. “You’re never really done,” concludes Ralf Neuser, “we still have a lot ahead of us, including work on master data, configuration, and the integration of other disciplines and trades.”
The Achenbach example illustrates the economic leverage that modularization can provide in mechanical engineering. A modular product structure gives rise to a modular system that enables reuse and has implications that extend far beyond the design phase. However, the development process does not end with the definition of a modular system. Product configuration, data, and integration with CAD, PLM, and ERP ensure that the modular structure can be utilized sustainably within the company.
