Preventing a Major OEM Engine Production Disruption

Background:

A European iron casting supplier supporting a major North American automotive OEM experienced severe operational disruption following labor conflict, equipment failures, and the loss of critical technical personnel. Production performance deteriorated rapidly, exhausting the supply pipeline supporting the OEM’s engine plant and forcing emergency logistics measures to sustain vehicle production.

Crossover Solutions was engaged to conduct a rapid operational assessment to determine the root causes of the disruption and define a practical path to stabilize production and restore supply continue.

Critical Issues:

• Production performance consistently below OEM demand
• Depleted supply pipeline and growing backlog of engine blocks
• Loss of experienced maintenance and technical personnel
• Equipment reliability challenges affecting casting operations
• Machining operations acting as the primary production constraint
• Limited operational visibility and performance management discipline

Our Approach:

Crossover conducted a structured on-site operational review to characterize plant capability, identify the true production constraints, and define the actions required to stabilize supply.

The engagement focused on production capacity, equipment reliability, workforce capability, and operational execution across casting and machining operations.

Key Actions:

• Increased machining throughput through extended operating schedules and improved production planning
• Restored equipment reliability through targeted maintenance recovery and procurement of critical spare components
• Established casting buffers to protect machining operations and enable recovery activities
• Implemented structured performance tracking to improve operational visibility and daily execution

Results:

The prescriptive recovery plan enabled the supplier and its new ownership team to stabilize operations and restore supply continuity supporting the OEM’s engine manufacturing operations.

Production stability improved, operational discipline increased, and the supplier regained the ability to sustain production at required demand levels. Crossover continued to monitor progress and remained available to support implementation as required.