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Tier 1 – Exhaust System Manufacturer
Background
- Tier 1 Exhaust Systems Manufacturers and JIT Supplier
- Client requests review as manufacturing process were unable to meet demand
Key Business Issues
- New equipment installation
- High Direct Labor Turnover
- High Skilled Labor Turnover
- Plant Manager left the team
- Outsourced Maintenance did not perform
Results
- Improved throughput with a combination of hands-on technical skilled trades and production supervisory staff
- Reduced OT from 24/7 to meeting demand in 5 days
- New product launch, PPAP approved
- Restructured Materials department, ensuring supply contracts and deliveries met expectations
- Coach/Mentor role for new leadership team
- Implement performance management systems
- Restructured maintenance department
- Implement Preventive Maintenance systems
- Lead IATF Certification
By the Numbers
100%
On time delivery improvement to 100%
$40K per week
Inbound / Outbound Premium Freight Reduction from $40k/week to $0
$65k per week
Overtime Reduction by $65K per week