Global Automotive Manufacturer
Transformed operations for a leading automotive OEM, achieving over $200M in annual cost savings while improving delivery performance and enabling successful new product launches through supply chain redesign and lean manufacturing implementation.
The Challenge
A leading global automotive OEM faced severe supply chain disruptions and rising costs. Multiple plants were underperforming, inventory was misaligned with demand, and profitability was under pressure. The CEO needed to cut operating costs by 10–15% while maintaining production quality and ramping up upcoming new product launches.
Our Approach
We conducted a rapid, organization-wide diagnostic, mapping out the end-to-end production network. Working with executives, we redesigned the supply chain by consolidating vendors and introducing advanced logistics planning. We implemented lean manufacturing techniques on factory floors and embedded predictive analytics for inventory management. Simultaneously, we aligned factory capacity with new model launches and retrained teams on best practices.
The Impact
Within 12 months, the client achieved over $200 million in annual cost savings, exceeding targets. Inventory levels dropped by 20% while on-time delivery improved 15%. The improved processes and real-time analytics enabled the company to hit its launch deadlines without additional overtime. Senior leadership credited the engagement with revitalizing operations and establishing a scalable model for continuous improvement.
