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Tier 1 – BIW
Background
- Tier 1 - Body in White Supplier, EU Based Company, New Facility Launch
- Cold Stamping, Hot Stamping, Assembly Operations - new steel technology
- Fulfillment compromised to multiple customers
- Failed launch of new product
- Unable to meet demand
Key Business Issues
- Poor understanding of technology and process
- Quality issues mounting, safe launch failing — no comprehensive QRQC
- Inexperienced leadership team
- Cultural difference between Parent Co. and local workforce
- Multiple Customer shutdowns
Results
- Inserted technology experts to work through operational challenges 24/7 — management, skilled trades, quality engineering, maintenance
- Inserted HR Team to champion hiring and training initiatives
- Coach, Mentor, Do - grassroots philosophy to get the plant back on track
- Elimination of 225 3rd party quality personnel in safe launch
- Within 4 months, corrected significant quality issues, tooling issues, process issues — resulting in achieving R@R, no shutdowns
By the Numbers
< 75% to 100%
On time delivery improvement from < 75% to 100%
> 4.0M
Premium Freight reduction > $4M
> 225
Premium 3rd Party Quality Safe Launch staff reduction > 225 people