Operational Excellence

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