
Driving Success in Challenging Times: Overcoming Escalations at an Automotive Supplier
Amidst the complexities brought about by the COVID-19 pandemic, a Tier 1 automotive supplier faced a critical situation during the launch of a new production line at their European facility. As a trusted partner, AC&C swiftly stepped in to address the arising challenges and restore operational efficiency. With our expertise and tailored solutions, we quickly identified and resolved the issues hindering the successful start-up of the production line. Through collaborative efforts and a keen focus on problem-solving, we effectively minimized downtime and optimized the manufacturing processes. As a result, our client experienced a significant increase in profitability, enabling them to successfully meet the demands of automotive manufacturers across three continents with a just-in-time and just-in-sequence delivery approach. At AC&C, we are committed to delivering exceptional outcomes, even in the face of adversity. Our proven track record of resolving complex situations and enhancing operational performance sets us apart. Contact our consultants today to discover how we can drive success for your automotive business and navigate challenges with confidence.

Challenge
Navigating Complexities and Unleashing Potential: Overcoming Challenges in New Product Production Introducing a new product on a brand-new production facility is a daunting task, and when compounded by the complexities imposed by the global COVID-19 pandemic, it becomes even more demanding. Our client, facing these exact challenges, encountered significant hurdles during the startup and post-SOP phases. Adding to the complexity, travel restrictions prevented planned project personnel from entering the country, further straining the plant and project organization. As a result, production operations experienced ongoing escalations that persisted for over a year. Despite the wealth of data generated by the plants, only a fraction of it was effectively utilized in root cause analyses. The problem-solving processes primarily relied on expert knowledge and a time-consuming ""trial and error"" approach, hindering the resolution of underlying issues. At AC&C, we thrive in the face of complexity. By leveraging our expertise and innovative methodologies, we worked closely with our client to address these challenges head-on. Our data-driven approach allowed us to uncover critical insights hidden within the vast amount of available data, enabling us to identify root causes more effectively. Through our streamlined problem-solving processes, we facilitated a shift from guesswork to evidence-based decision-making, significantly reducing the time and effort required to resolve issues. Our commitment to continuous improvement and our ability to adapt to unforeseen circumstances proved vital in overcoming the hurdles posed by the pandemic. By implementing robust strategies and optimizing production processes, we helped our client regain stability and achieve operational excellence. Together, we transformed their escalation-ridden production environment into a thriving and efficient operation. Experience the AC&C difference. Contact our consultants today to unlock the untapped potential within your manufacturing operations and navigate the most challenging circumstances with confidence.
Solution
Driving Performance and Quality: A Tailored Solution for New Product Production To address the challenges faced by our client during the production of a new product on a recently established facility, AC&C deployed a multi-faceted approach focused on three key areas: plant availability, cycle time stabilization, and product quality assurance. Our team of experts worked collaboratively with the client's teams, forming a task force dedicated to resolving the issues at hand. Through daily coordination and weekly prioritization sessions, we ensured a synchronized and targeted approach. Central to our solution was the utilization of the cutting-edge MOZAK platform. This powerful tool enabled us to harness and analyze the vast amount of product- and process-related data generated throughout the manufacturing process. By leveraging advanced data analytics and statistical techniques, we identified crucial cause-effect relationships, enabling evidence-based decision-making and problem resolution. The systematic analysis of data and facts provided invaluable insights into the underlying issues, enabling our client to make informed decisions and implement effective corrective actions. Through our collaboration and the implementation of the MOZAK platform, we successfully achieved tangible improvements in plant availability, cycle times, and product quality. Our agile problem-solving approach, driven by data and supported by our expert guidance, allowed for quick adjustments and continuous optimization. This, in turn, resulted in increased production stability, enhanced efficiency, and elevated customer satisfaction. Experience the power of data-driven solutions. Contact AC&C today to discover how our expertise and innovative methodologies can help you overcome challenges and unlock the full potential of your production operations. Together, we can drive sustainable growth and achieve operational excellence.


Results
Driving Profitability and Building Trust: Unleashing the Potential of New Product Production Through our dedicated efforts and collaborative approach, our experienced team successfully guided our client towards complete de-escalation within a remarkably short span of eight months. The results achieved during this transformative journey have been nothing short of remarkable. One key area of focus was the Overall Equipment Efficiency (OEE), a critical metric that measures the utilization and effectiveness of the production equipment. By implementing targeted improvements and optimization measures, we were able to elevate the OEE from under 40% to an impressive level exceeding 90%. This substantial enhancement in operational efficiency had an immediate impact on the bottom line, leading to a substantial increase in profitability for our client. Moreover, the resolution of the escalation issues and the remarkable increase in OEE played a crucial role in restoring the trust of the Original Equipment Manufacturer (OEM). With the regained trust and the successful resolution of the challenges, our client has been able to foster a stronger partnership with the OEM. This newfound trust has resulted in the initiation of new joint projects, opening doors to future growth and collaboration. The remarkable achievements of our client's transformation journey stand as a testament to the effectiveness of our comprehensive approach and the value of data-driven decision-making. By leveraging our expertise and harnessing the power of advanced analytics, we have not only resolved the immediate challenges but also unlocked untapped potential, paving the way for sustained success and profitability. Discover the transformative power of collaboration and data-driven solutions. Contact AC&C today to explore how our proven methodologies and experienced team can help your organization overcome obstacles and achieve extraordinary results. Together, we can turn challenges into opportunities and drive your business towards a prosperous future.
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