Case Study

Automotive / Body


  • 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


  • 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