Automotive Supplier
Our Client a major first tier automotive Supplier were suffering from poor on time delivery and quality in their 2nd tier supplier. This ongoing problem resulted in high levels of rework, cost and poor on time delivery to our OEM Customer. JBA were asked to facilitate a Practical Problem Solving workshop to help solve the issues, which resulted in a cost avoidance of £250.000 pa.
Before
Over time, supplier conformance issues had resulted in severe production disruption for both our client the 1st tier Supplier and their prestigious OEM.
As the problems within the supply chain had not been resolved there was severe disruption to the business. High levels of rework and scrap at nearly 50% yield combined with emergency shipping costs, non conformance costs at £75.00 per non conformance, with a lack of on site customer containment actions.
"The assessment showed how much potential there was to achieve, major cost benefits and how the lean principles would support the changes which were realistic and achievable, sometimes it just takes fresh eyes to see the potential."
Manufacturing Manager
After
- Customer protected.
- Team PPS report completed, root causes defined and understood, robust process and corrective action controls implemented.
- TPM strategy defined and reviewed.
- Countermeasures audited to measure effectiveness and ensure issue prevention.
- Rework at supplier and OEM PPM eliminated.
- Visual aides deployed.
- Customer satisfaction of supplier management controls in place.
- Customer employees trained in supplier evaluation processes.
