Case study on continuous improvement in the automotive sector

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.

Background

Our 1^st 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

• 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

• 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

Khalid Said
Senior Consultant I IMIG UK Ltd.

For further information please contact us either by mail: marketing@imig.com or by phone: +49 7152 928 460.