Industry
Special-purpose machinery
Country
Italy / Germany
Scope
Process documentation
Duration
2-week training rollout
A manufacturer of special-purpose machines was launching a new product family into simultaneous production at two facilities — one in Italy, one in Germany. No assembly work instructions existed for the new product. Without consistent documentation, each facility would develop its own assembly practices independently, and quality divergence between the two production lines was a certainty from the first day of production. The documentation needed to be ready before the lines opened, bilingual, and in a format that operators could use directly on the shop floor.
GFE produced 47 assembly work instructions covering every major stage of the assembly process. Each instruction was illustrated with 3D step images generated directly from the existing CAD models, which allowed visual clarity without additional photography or illustration work. Documents were formatted for tablet use on the shop floor — portrait layout, large images, minimal text per step. The full set was produced in both Italian and German as a single unified document, ensuring that both facilities followed identical procedures. Training was completed at both sites within two weeks of delivery.
47
work instructions
IT + DE
one unified document
3D
illustrated from CAD
2 weeks
both sites trained
Having the same documentation in both plants eliminated the ‘we do it differently here’ problem from day one.
GFE engineers spend time on the production floor before making recommendations — understanding the actual process before proposing changes.
Engagements are scoped around specific production targets — scrap rate, cycle time, first-article pass rate — not general improvement initiatives.
All process documentation and work instructions are structured for ISO 9001 audit and operator use — formatted for the shop floor and ready for external review without additional preparation.
Work instructions and process documentation are produced in English, German, and Italian — ready for use at multi-site international production facilities.
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Our customers
Our company produces safety-relevant welding assemblies for the chemical and pharmaceutical industry.
Due to the fact that it has become increasingly difficult to find good engineers and designers for our design department at our location in rural Münsterland, we set out at the end of 2018 to look for new external solutions in the service market.
I really appreciate GFE’s flexibility and openness for new challenges. They are not afraid to start a new journey.
If I think about the external circumstances of the project we started together, we reached a learning curve and relating results that I did personally not expect.
We required additional capacity and professional support for our R&D Team especially for a new product development.
And GFE Solutions offers capable support by very well-educated engineers. High professionalism. On time delivery and great communication (native German speakers).
We are the company in constant need for plants for research or pilot projects of our clients. Last year we were working over the order in the field of medical technologies, which we succeeded to realize, including thanks to efforts of GFE Solutions team.
We were in need of help with our design department ressources and we had to move fast, internal ressources were not available and GFE was able to help quickly and competent. GFE works with dedication to the very needs of its customers, has a variety of specialists and has offered a fair price on a transparent basis.
We were looking for additional engineers to expand our construction capacity. You seemed to be a young, motivated Team and except your professional expertise, your personal commitment made me confident to work with you. The cooperation has been seamless and very productive from the start. We are happy with the results.
GFE Solutions is a specialized engineering services company. Our engineers are mainly from Eastern Europe – to our customers we offer onsite- and offsite-engineering-services. All our specialists speak and write fluently English, some of them German and other languages.
Phone: +48 798 763 604
For general enquiries: info@gfe-solutions.com
For commercial requests: inquiry@gfe-solutions.com
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