Back to Case Studies
OEM Supply Chain – Interior Fabric Supplier
Background
A Tier 1 manufacturer of floor, deck, and shelf carpet engaged our team to support proactive supply risk mitigation. The goal was to stabilize operations and ensure continuity across critical components amid ongoing supply chain disruptions.- Aging equipment failing to meet performance requirements.
- Facing complications in new equipment installation.
- Financial instability, including an active bankruptcy filing .
- Disengaged and ineffective leadership impacting operations.
- Elevated employee turnover across key functions.
- Shortage of qualified skilled trades personnel.
- Strained relationship with OEM/Tier 1 customer, impacting collaboration and performance.
Results
- Achieved significant throughput improvements, enabling full production requirements to be met within a 4-day workweek
- Eliminated the need for 24/7 operations and overtime through process optimization
- Stabilized the launch of new equipment by deploying skilled technical resources
- Improved Customer relationships
- Successfully transitioned all products and processes to new suppliers with minimal disruption
- Led and supported re-launch PPAP activities to ensure compliance and readiness across the supply base
By the Numbers
$200M
Risk Mitigated $200M of OEM Exposure
< 65% to 100%
On time delivery Improvement from < 65% to 100%
< 3 Weeks
Business Transfer, re-launch < 3 weeks