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OEM Supply Chain – Class A Molding and Assembly
Background
- Tier 1 Class A Injections Molding and Assembly
- Client requested operational assessment as the supplier was behind launch targets
Key Business Issues
- Underdeveloped molding process
- Out of control metallizing
- Secondary processes not capable
- Assembly line unbalanced
- Assembly not meeting quality expectations
- High direct labour turnover
- Poor material value stream layout
Results
- Dialled in molding process, mold set up and changeover management
- Brought in metallizing expertise
- Repositioned all materials into supermarkets for line presentation, eliminating stock outs
- Established operational performance criteria, including deep dive quality reviews and root cause corrections
- Scheduling secondary process to ensure shared asset availability, improving efficiency
- Manufacturing performance improvement — meeting contract in 5 days with no additional capital requirements
- Replaced assemblies on all previous yard hold vehicles
- No lost vehicles
By the Numbers
>50%
Efficiency Improvement of >50% in first 20 days
0
No Lost vehicles at OEMS
24/7 to 5 days
Overtime Reduction — 24/7 reduced to 5 day operations