Case Study

Automotive Industry—Tier 1

Company Profile: Largest automotive safety prod-

ucts company in the world, with about 85 sites in 29
countries including Canada, US, Mexico, China and
Brazil. Sites include batch processing of explosive gen-
erants & discrete manufacturing of components. Ap-
proximate annual revenue is $2.9B.

Challenge: Lowering the cost of product and increasing

throughput while preserving jobs in the US. OEM’s are
constantly driving suppliers to lower costs and hold
them to strict standards regarding quality and delivery
timing. The need to reduce labor minutes per unit
(LMPU) from 5 to less than 1 was the only way to meet
the goals set by the leadership team and to preserve the
jobs doing this work within the US.

Solution: Standardize all 15 of the manufacturing sites

on Lean Dispatch to identify opportunities to reduce
LMPU and isolate & resolve impacts to production driv-
ing up LMPU or other costs. This also needed to allow
for the unique methods used at each of the sites. Stand-
ardized key metrics to allow meaningful perfor-
mance monitoring but allow
unique local metrics based on the
type of work in the plant.
 Case Study

Value and Benefits: Increased Operational Availability. Real-time

visibility and management of the floor. Detailed data during responses
or for drill-down on paretos. Problem solving became a self-interest to Leading2Lean has con-
the plant floor staff. Reduced MTTR as well as extend MTBF signifi- tinued to develop and
cantly. evolve Dispatch and our
plants are deploying it
as our standard”. – Phil
Anderson, Dir of IT

Bottom Line: Overall 80% increase in ma-

chine uptime & 80% reduction in LMPU
and product costs. 10% recurring annual
improvement goal & achievement in each
department. $90M over 10 year period.
Other improvements include:
 Over 100,000 Continuous Improvement
suggestions implement in one year.
 Overall customer PPM reduced in
88% in 2 years.
 `100% Productivity improvement over
10 years.
 Reduced overall material cost/unit by
20% and production scrap by 34%
over 3 years.

About Leading2Lean
Leading2Lean is a leading provider of global cloud visual manufacturing exe-
cution solutions that drives systematic improvements and key results to help
manufacturers achieve operational excellence. Leading2Lean is changing
the manufacturing industry so firms can build successful and sustainable
continuous improvement cultures by providing leading technology and meth-
ods that teach and empower people to achieve operational excellence and
efficiency. You can visit us at www.leading2lean.com or call us at 1 877-225-
5201.