In today’s competitive automotive industry, operational efficiency isn’t just an advantage — it’s a necessity. At KCG, we partner with our clients to overcome production and logistics challenges, streamline operations, and unlock performance gains. One of our recent success projects perfectly illustrates how targeted interventions can deliver measurable results.
Challenges on the Shop Floor
Our client, a key player in the automotive supply sector, was facing several operational roadblocks:
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High Internal Reject Rate: 8% of production output was being scrapped.
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Suboptimal Overall Equipment Effectiveness (OEE): Performance stood at 82%, below industry benchmarks.
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Production and Logistics Inefficiencies: These were hindering daily output and impacting inventory management.
Clear Objectives for Impact
To turn the situation around, KCG set out with a focused mission:
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Boost OEE and optimize workflows
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Reduce scrap and minimize downtime
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Enhance logistics and inventory processes
Our Approach and Methods
KCG deployed a hands-on, structured improvement strategy, emphasizing both analytical rigor and on-the-ground execution:
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Focused Problem-Solving & Execution: Leveraging lean methodologies to tackle root causes head-on.
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Shop Floor Optimization: Enhancing workflows, improving maintenance routines, and maximizing machine availability.
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Logistics & Supply Chain Improvements: Streamlining inbound/outbound flows and tightening inventory control.
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Transparent KPI Tracking & Reporting: Real-time data visibility to drive accountability and progress.
The Results Speak Volumes
Through collaborative effort and disciplined execution, KCG helped the client achieve remarkable performance gains:
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Internal Reject Rate: Reduced from 8% to 4.5%
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OEE: Improved from 82% to 86%
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Daily Output: Increased from 470 to 520 pieces/day
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Inventory (DOH): Strengthened from 2.0 to 7+ Days on Hand
A Proven Path to Operational Excellence
This project exemplifies how targeted action, driven by data and executed on the shop floor, can transform operational outcomes in a demanding industrial environment.
Is your operation ready for the next level of performance?
Let KCG help you unlock hidden potential in your processes. Contact us today to start your journey toward operational excellence.
