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Case Study | Supplier Performance Intervention
Automotive OEM Powertrain | Tier 1 Interim Management
Abstract
A tier one manufacturing company was unable to consistently ship quality products causing major disruptions shutting
down several Automotive OEM transmission and engine plants. TPS was engaged to manage operations, implement
immediate corrective actions and diagnose systemic problems to improve manufacturing, operations and quality.
Challenge
• Areas of management responsibility were not well defined.
• Tier 2 suppliers in the value stream were not provided with clear deliverables and therefore were not producing parts
that met customer requirements.
• Resolve systemic problems and develop revised operations, quality and manufacturing production processes that
would error-proof all systems in the value stream.
Execution
• Development and management of an interim product layered containment process to ensure the OEM did not
experience plant disruptions.
• Reconfigured the plant floor allowing families of products to be manufactured in focused factory cells.
• Implemented error-proofing , incoming inspection, PM system, formalized PCPs, updated PFMEAs and Control
Plans and in-process traceability.
• Developed and implemented a quality metrics documentation process intended to measure key characteristics
throughout the process.
• Recruited new Quality Manager that continued the transition into the new quality system.
Result
New and existing plant leaders were mentored to adhere and sustain the developed plant manufacturing operations,
production management and quality system. Most important, there were no further major disruptions in any of the
Automotive OEMs Powertrain manufacturing locations.