|
Client: Manufacturer of automotive convertible top assemblies
Challenge: Convertible top supply program operating at no margin; quality performance issues; eliminate late shipments
Our Role: Develop, implement and manage an improvement plan to reduce costs, improve the quality, and improve communications with the customer
Implementation Strategy:
- Develop a focused factory strategy and opened a facility near the customer and dedicated to their products
- Deploy Key Lean Manufacturing Tools
- Visual Factory Management
- Mistake Proofing
- Single Part Flow / Cellular Manufacturing
- Develop and Deploy Business Operating Systems and Balanced Scorecards
- Modify fabric cutting techniques to improve material utilization
- Implemented new manufacturing techniques and deployed 5S methodology
Results achieved:
1. Reduced delivered defects by 100%
2. Improved gross margins from 0% to 28%
3. Received “Most Improved Supplier” award from customer for 2002
|
