34% reduction in production cycle time across 6 facilities.
The Challenge
A leading automotive parts manufacturer was losing ground to competitors due to inconsistent production schedules, high rework rates, and a lack of standardized processes across its North American facilities.
Our Approach
We conducted a full operational diagnostic across all six plants, mapped every production workflow, and identified 14 critical bottlenecks. We then redesigned the core scheduling and quality control processes and ran a 90-day change management program to embed the new systems.