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Stabilizing Supplier Performance for a Successful Product Launch – Interior Systems

Case Study

Interior Systems - Carpet & Acoustic Parts

Services Used
  • Performance Management
  • Supply Chain Risk Management
  • Targeted Performance Improvement initiatives
  • Technical and Skilled Challenges

Background:

An OEM encountered significant launch risks for a new vehicle program due to performance challenges with four critical suppliers. Crossover was brought in to identify gaps, implement corrective measures, and drive execution, ultimately ensuring the achievement of Run@Rate (R@R) certification for a successful product launch.

Key Business Issues:​

  • Inexperienced Tier 1 suppliers struggling to meet OEM standards.
  • Equipment issues causing inefficiencies and defects.
  • Misalignment with OEM requirements, impacting quality and readiness.
  • Staffing shortages disrupting production stability.

Approach:

To stabilize supplier performance and enable successful R@R, Crossover led:
  • Comprehensive gap analysis, identifying deviations, defining a tactical change mandate, and executing corrective actions.
  • Targeted meetings, providing clarity and transparency to align suppliers with OEM requirements.
  • Dedicated technical teams, resolving critical process issues.
  • Process validation under series conditions, identifying and mitigating risk factors.
  • Structured governance model, driving issue resolution through regular team meetings and escalation protocols.

Results:

  • Successful ramp-up of the new vehicle program, with no delays in production.
  • Stable, compliant production processes across all four suppliers, securing R@R approval.
  • Achieved scrap rate and OEE targets, improving operational efficiency.
  • Knowledge transfer program established, ensuring long-term supplier capability development.
  • OEM-mandated training programs implemented, covering production requirements and preventive maintenance best practices.

Through hands-on execution and strategic oversight, Crossover enabled the OEM to mitigate supply risks, achieve program stability, and build supplier capability for sustained success.

By the Numbers

4 Suppliers
stabilized, ensuring seamless vehicle launch
100%
of production processes validated and released in compliance with OEM standards
0 Delays
in delivery, securing Run@Rate (R@R) certification and production readiness