Case study on continuous improvement in automotive
Our 3-day system assessment has supported our case in convincing our client that running practical problem-solving projects to solve production arrears and maintain OTIF will never succeed without robust lean foundations. Here we share details of a continuous improvement in automotive case study.
Background – continuous improvement in automotive
Our 1st tier supplier to one of the largest automotive company was facing multiple constraints which stopping from meeting their delivery, quality and financial targets.
- Arrears 329 (-2.5 days)
- RFT 85% against 95% target
- Production Achievement 50%
- Plan Adherence 37%
- Child Parts Shortages = 6 at end of shift
Improvements – continuous improvement in automotive
- Visualise progress – one common view
- Highlight blockers instantly
- Leadership presence on the shop floor
- Engage direct workforce
- Remove motion & waiting wastes
- Daily readiness check
- Quick & short RCA’s
- 5S activities
- Introduced a standards before any initiatives
Results – After 6 weeks – continuous improvement in automotive
- 95% of all actions closed
- Arrears 119 (-0.9 days) → improved by 64%
- RFT 92% against 95% target → improved by 7%
- Production Achievement 70% → improved by 20%
- Plan Adherence 57% → improved by 20%
- Child Parts Shortages = 0 at end of shift → 100%
- Well engaged workforce
Employees feedback
- Great results well received
- You have managed to engage a direct workforce
- It’s motivating to see leaders on the shop floor and giving support to long-lasting problems
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