Client

DELPHI

Auto steering systems manufacturer

Objectives

The objective was to reinvigorate and expand the stalled implementation of a lean-based production system in seven separate plants.

Solutions

TSD began with a series of training sessions for plant and union leadership to excite, inform and align each facility to the benefits of a lean environment. This was followed with current and future state maps, along with business cases, revealing the potential for improvement. Then TSD instituted a controlled deployment of lean tools and techniques to improve flow, increase reliability and raise quality, all the while embedding cultural change in the day-to-day processes of each workforce.

Outcomes

The program resulted in the savings of over $28 million per year, the development of a corps of internal lean experts to propagate lean processes and culture, and a 10-fold reduction in defects. In addition, there was a measurable improvement in workforce morale as many facilities achieved numerous internal and external awards.

Return on Investment

11 fold return