Securing North American Launch for a Tier 1 EV Supplier

Background:

A global Tier 1 supplier of EV underbody structures selected Mexico for its first North American manufacturing operation, introducing an unproven forming technology under an aggressive OEM launch schedule. With no regional footprint, no OEM history, and limited program governance, the supplier turned to Crossover Solutions to secure a successful market entry, on time, at quality, and at full capacity.

 

Critical Issues:

• No operational presence or manufacturing history in North America
• First engagement with a North American OEM operating under strict compliance and traceability standards
• Simultaneous requirements for facility build-out, workforce development, and production readiness​
• PPAP approval required during live production ramp-up

Approach:

Crossover deployed an integrated launch program combining strategic direction with hands-on operational control. We built the supplier’s North American capability from the ground up, establishing the operational footprint, installing OEM-grade systems, and driving disciplined execution through every stage of readiness.

Key Actions:

• Defined market entry and operational roadmap aligned with OEM milestones and regional regulatory standards.
• Mobilized cross-functional launch team to oversee facility startup, supplier integration, and equipment commissioning.
• Installed OEM-compliant quality and performance systems to detect and contain variation at source.
• Led the PPAP process in parallel with production, achieving certification without interrupting ramp-up.
• Deployed digital monitoring and escalation systems to maintain daily control of throughput, quality, and delivery.

Results:

Crossover ensured the supplier’s seamless entry into the North American EV sector by:

• Launching full production within OEM lead time requirements.
• Achieving stable capacity and delivery performance during ramp-up.
• Meeting 100% of OEM quality and performance metrics.
• Securing PPAP certification during live production.

This case demonstrates Crossover’s ability to de-risk new market launches, accelerate operational maturity, and embed quality and performance discipline from day one, transforming a first-time market entrant into a trusted North American supplier.