Müller Präzision GmbH: 5S audit score 38→87, €1.232M efficiency gain in 5 months
5S productivity breakthrough: €1.2M cash gain in five months without CAPEX
Customer & challenge
At the Stuttgart plant, a Q4 2025 internal audit scored 5S at 38/100; bench search time averaged 14 min/shift, unplanned downtime was 14.2%, and scrap cost ran €187,000/month.
Hidden inefficiency cost: 500 employees × 22 days × 8 hours × 12% time loss = 10,560 hours/month Fully loaded hourly cost (German automotive, IG Metall scale): €35/hour Monthly cash-flow loss: €369,600
Solution
SectorCalc Trust Trace™ 5S Audit & Efficiency Loss Cost Converter module was deployed.
Implementation standards: - DIN EN ISO 9001:2015 Clause 7.1.4 (Process environment) - VDI 2067 Part 3.2 (Economic production evaluation) - JIPM TPM Seiri-Seiton-Seiso-Seiketsu-Shitsuke audit protocol - Sector: Automotive supply chain, IATF 16949 aligned.
Results
| Metric | Before | After |
|---|---|---|
| 5S audit score | 38/100 | 87/100 |
| Scrap rate | 8.2% | 3.1% |
| Unplanned downtime | 14.2% | 5.8% |
| Bench search time | 14 min/shift | 3.2 min/shift |
| Monthly efficiency loss | €369,600 | €123,200 |
Tools used
Statement
“SectorCalc's cost converter model turned 5S from a cleaning project into a cash-flow line item on the CFO report. €1.2M in five months — in our pocket with process discipline alone, without any CAPEX.”
Composite illustrative scenario based on typical sector patterns — not a verified audit of the named business. Not financial, legal, or engineering advice.