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1st Tier Automotive – Case Study 1

1st Tier Automotive Lean Deployment

 

GENEO’s expertise in the automotive industry is extensive, thanks to the ex-Toyota employees in our team.

Through hands-on experience transforming projects into successes, our lean consultants are able to bring about change and reduced costs along the full line, including Paint, Manufacturing, Weld, Logistics, Engineering, Assembly.

Client

1st Tier Automotive

Scope

100 day recovery to prevent closure

Diagnostic

Week-long diagnostic with VSM focus

Actions

  • Immediate containment loops in quality process. End of line inspection augmented to capture issues and feedback to point of cause
  • Introduction of Info Centres to drive accountability
  • Short interval control on key lines to drive delivery focus
  • CRASH team to resolve problems rapidly and inject countermeasures into design and ME
  • Logistics intervention to overcome ERP generated haemorrhaging of inventory and WIP
  • Standardised Work for all processes on production lines to contain issues

Results

  • 7 of 10 balance scorecard targets reached in the 100 days
  • Customer retained and agreed to ongoing, longer term action plan
  • Line shortages eliminated using pull systems and market places
  • Profitable in third month of engagement
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Trialled and perfected transformation method

GENEO has developed a unique deployment model to accelerate your Lean transformation. Contact us to understand how GENEO can help boost your Lean transformation.
Read which industries our Lean Consultants have helped

Continual success stories

GENEO continues to grow its business based on the great results we achieve with our clients. No engagement is ever the same, each one presenting a unique set of challenges for our team, challenges that we heartily accept and overcome jointly with our clients.
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We are training leaders to make a difference by leading Lean with the appropriate behaviours to make a significant difference to their Continuous Improvement culture. It’s all about people and we are all about people.
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