Ramp-up and delivery assurance for panoramic roofs

Situation:

The supply of panoramic roofs to a major automotive customer was at significant risk. Deliveries could only be ensured in small quantities through special transport (SoFa). The Overall Equipment Effectiveness (OEE) was well below 85%, and there was a shortage of trained staff, coupled with high turnover rates.

Project Period:

December 2017 to July 2018

CONSOTIUS Mandates:

Provision of VP Operations, quality and analysis specialists.

Objectives:

• Ensure serial delivery capability.

• Implement a 4-shift system and recruit and train the necessary staff.

• Establish a training center for line workers.

• Expand line capacity with an additional manual production line.

Challenges:

• The production line was not yet ready for serial production at the scheduled Start of Production (SOP) and awaited final approval from the customer.

• Simultaneous production for multiple customers on the same line.

• Quality had to be ensured through the use of three firewalls.

• Daily coordination and reporting to the customer.

• Building the 4th shift took three months.

Achievements: 

• From April 2018, 100% on-time delivery of all customer orders was secured.

• Line OEE reached the targeted 85% from April 2018.

• The training center was successfully established, and the 4-shift system was introduced by Easter 2018.

• The manual production line was built and successfully approved.

Conclusion:

Thanks to a structured approach and targeted measures, CONSOTIUS successfully addressed the initial challenges. Not only was the production line made serial-ready, but delivery capability and quality were also sustainably ensured. With the successful establishment of the training center, the introduction of the 4-shift system, and the optimization of production processes, customer orders were fulfilled on time, and operational targets were met. This project is a testament to how tailored solutions and professional support can stabilize and optimize critical production processes effectively.