German OEM: Supplier Qualification in Mexico

As part of a four-month project, we supported a German OEM site in Mexico in qualifying a supplier with the aim of sustainably improving production stability and delivery reliability.

OUR SERVICES

  • •Performing a comprehensive weakness analysis
  • •Defining and managing five work packages
  • •Facilitating workshops (e.g., WSA, SMED, Brainstorming)
  • •Introducing fundamental Lean elements in production
  • •Project management including weekly reporting and monthly steering committee meetings
  • •Daily operational support in production meetings

PROJECT SCOPE

On-site support for the qualification measures of two redi employees for the sustainable optimization of production processes and the establishment of a structured business system.

Duration: 4 months

THE CHALLENGE

Production was characterized by opaque, non-standardized processes. This led to OEE drops in pre-assembly and final assembly, poor delivery performance, and a highly reactive troubleshooting approach without sustainable action management.

OUR SOLUTION

  • •Performing a weakness analysis with subsequent clustering
  • •Defining five targeted work packages including responsibilities
  • •Tracking the implementation of measures with MS Project
  • •Facilitating and providing methodological support for problem-solving workshops
  • •Introducing central Lean methods in manufacturing (e.g., TPM, 5S, Jidoka)
  • •Establishing weekly reporting and a monthly steering committee
  • •Attending daily production meetings

The Result

Significant improvement in delivery reliability

Stabilization and increase of OEE in pre-assembly and final assembly

Improved quality metrics in pre-fabrication and final assembly

Introduction of a business system with sustainable standards: Total Productive Maintenance, 5S, Visual Management, Standardized Work, Jidoka Principles