for the leading truck manufacturer to resolve constraints in assembly and logistics, meeting critical deliveries of military vehicles to the front-line. Organized team and processes to enable flow in vehicle assembly and logistics, yielding in 25% shorter cycle-times and 60% higher first-pass yield within the first two months of the Lean transformation program. Key success factors included training people in methods and tools, moving materials not all-at-once but in short cycles at a 20-minute pitch, while formally addressing problems as part of the 4-hour performance management routine. The disciplined application of Lean principles brought the 40%-delayed project back on track: all 83 vehicles for the Canadian Army were shipped on time to Afghanistan, while people involved in the transformation became firm believers of Lean principles and practices.
Facts & Figures
- Industry: automotive
- Scope: operations
- Locations: France, Germany
- Engagement: 6 months
- Support: 165 days x 2 people
- Role: interim manager
- Speed: -25% overall lead time
- Quality: +60% first-pass yield
- Delivery: from 40% delay
to 100% shipped on time
Client Feedback
"You have ccomplished something big that keeps on delivering. Production runs at an excellent level and new improvements are noticeable every single day. Your work has definitely beard fruits. Thanks again for your engagement and commitment."
"You as one man have made more difference to this project than the entire team that you have seen, as well as the ones that you have not."