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Reviving Reliability Post-COVID Disruption
Background:
A Tier 1 supplier of large castings in Mexico faced severe operational challenges supplying multiple OEM lines which threatened their financial stability and customer trust.Critical Issues:
- Significant manpower reductions, including key technical staff, during COVID shutdown.
- Technical staffing, knowledge levels and systems not fully recovered.
- Shortages causing millions in weekly losses from off-lined/unmet vehicle production schedules.
Approach:
XO conducted a full assessment and deployed a comprehensive operational turnaround strategy with the objective to address immediate shortages and low OEE while establishing long-term technical and operational support.Key Actions Include:
- Assigned a focused operations team to track OEE hourly, addressing issues in real-time across critical process points.
- Deployed technical experts to tackle specific process and tooling challenges.
- Rebuilt basic systems: equipment maintenance, tool repair, spare parts management, and reliability engineering.
Results:
Through assessments and identifications of key suppliers, increased communication and overall supply base optimization, Crossover was able to secure:- Stabilized operations, reversing devolved maintenance and reliability systems.
- Restored supplier reliability and OEM confidence.
- Positioned Tier 1 for sustained operational efficiency.
By the Numbers
$100M +
OEM annual contribution due to restored production
$2M+
in immediate operational savings for the Tier 1 from improved OEE