Operational Excellence

Automotive
Supplier
day(s)

CUSTOMER

  • Major Global  Automotive 1st tier of interior trim in Germany 
  • Approx. 250 employees over three customer lines
  • Components supplied –Instrument panel, Glove boxes, Door Panels and 100+ pass through mouldings included painted parts
  • Location: Germany

 

NATURE OF SERVICE 

  • Continual negative delivery performance against customer schedules 
  • Non-conforming/reject product. 
  • Lack of communication of issues 
  • No clear improvement roadmap evident/executed
  • Part Approval still in progress even though product past SOP
  • 27 tooling modification in progress

 

TARGET

  • Ensure consistent delivery against EDI schedules 
  • Improve customer confidence and communication by providing robust focus over 24 hour period 
  • Develop communication strategy between plant and customer 

 

TASKS

  • Measure and define the problem
  • Developed delivery tracker (symptom and causes) which identified several issues effecting multiple product lines eg:
  • BOP shortages (lack of knowledge on scheduling system)
  • Internal production planning (Logistics and Operations not communicating) 
  • Engineering change control (no co-ordination of action)
  • High scrap rate product lines (weak root cause analysis)

 

PROJECT KEY FIGURES

Improved delivery performance to 100% from 40%


TEAM

  • Executive Champion
  • Engineering Change Control Manager
  • Engineering Projects Manager
  • Logistics Manager
  • Quality Manager 

KEY ACHIEVEMENTS AND RESULTS

  • Reduced onsite defects on strategic components
  • No missed vehicles or line disruptions  at OEM
  • Plant continued to cause no disruption to OEM for next 18 months until change of senior management and failed engineering change control. 
  • BTM redeployed to work with new management team (Plant Manager, Quality Manager, Logistics Manager) to re-stabilise operations 
  • Requested to return by the 1st tier to assist in securing QSB Qualification (Quality Systems Basics) which was under threat due to above concerns. Development and implementation of action plan

 

For more informations: trigouk.info@trigo-group.com