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OEM-Directed Manufacturing Stabilization & Launch Recovery
Background:
A major automotive OEM requested an independent operational review of a Tier 1 supplier facing escalating quality and launch performance issues. Simultaneous launches, production transfers, workforce instability, and COVID-era disruptions strained operations, driving stamping variation, process instability, quality escapes, and increased customer concern around production readiness.Critical Issues:
- Escalating customer quality concerns and safe launch exposure
- Missed manufacturing processes and assembly escapes
- Excessive sorting, rework, and containment activity
- Stamping defects driving excessive WIP and operational instability
- Launch activities extending well beyond planned timing
- Limited indirect resources to support simultaneous launches and operational demands
- Incomplete process validation and capability studies
- Weld process instability and process change control gaps
- Weak systemic root cause execution and corrective action effectiveness
- Material flow congestion and manufacturing inefficiencies
- Lack of proactive layered audit systems tied to operational risk
Our Approach:
XO conducted an independent manufacturing and quality system assessment while deploying embedded operational leadership across multiple facilities to stabilize execution, assess operational risk, and restore disciplined performance management.Key Actions:
- Supported operations supervision, quality containment, and materials management
- Implemented QRQC escalation and structured problem-solving processes
- Supported poka-yoke validation and manufacturing process verification
- Assisted with launch readiness and operational stabilization activities
- Introduced layered process audit (LPA) methodology
- Enhanced PFMEA, control plan, and standardized work alignment
- Supported weld validation governance and process control improvements
- Improved production leadership structure, accountability, and training systems
- Assisted in PFEP and material flow optimization initiatives
Results:
- Stabilized manufacturing operations during active launch conditions
- Reduced operational and quality risk exposure
- Improved customer confidence and operational transparency
- Strengthened manufacturing process discipline and accountability
- Improved escalation management and QRQC execution
- Enhanced launch governance and process validation rigor
- Reduced operational congestion and manufacturing instability
- Improved management visibility to systemic operational issues
- Improved management visibility to systemic operational issues
- Established foundation for sustainable operational recovery and launch execution
By the Numbers
50+
Active Sort/Containment Conditions
3
Targeted sites for support (Alabama, Mississippi, and Tennessee)