Client

1st Tier Automotive

Scope

100 day recovery to prevent closure

Diagnostic

Week-long diagnostic with VSM focus

Actions

  • Immediate containment loops in quality process. End of line inspection augmented to capture issues and feedback to point of cause
  • Introduction of Info Centres to drive accountability
  • Short interval control on key lines to drive delivery focus
  • CRASH team to resolve problems rapidly and inject countermeasures into design and ME
  • Logistics intervention to overcome ERP generated haemorrhaging of inventory and WIP
  • Standardised Work for all processes on production lines to contain issues

Results

  • 7 of 10 balance scorecard targets reached in the 100 days
  • Customer retained and agreed to ongoing, longer term action plan
  • Line shortages eliminated using pull systems and market places
  • Profitable in third month of engagement

1st Tier Automotive Lean Deployment

 

GENEO’s expertise in the automotive industry is extensive, thanks to the ex-Toyota employees in our team.

Through hands-on experience transforming projects into successes, our lean consultants are able to bring about change and reduced costs along the full line, including Paint, Manufacturing, Weld, Logistics, Engineering, Assembly.

Trialled and perfected transformation method

GENEO has developed a unique deployment model to accelerate your Lean transformation. Contact us to understand how GENEO can help boost your Lean transformation.

Continual success stories

GENEO continues to grow its business based on the great results we achieve with our clients. No engagement is ever the same, each one presenting a unique set of challenges for our team, challenges that we heartily accept and overcome jointly with our clients.

Leadership training

We are training leaders to make a difference by leading Lean with the appropriate behaviours to make a significant difference to their Continuous Improvement culture. It’s all about people and we are all about people.
Reduce maintenance turnaround time by 50%!
  • TEMPO is a system that has been developed to radically reduce the time taken to perform complex maintenance activities on fixed assets or fleet. It is a simple yet intelligent way of organizing your maintenance activities to complete the maintenance turnaround in half the time.
  • By organizing work sequences for trades/technicians and building critical paths and dependencies, TEMPO quickly highlights lost time opportunities in the overall planned turnaround.
  • Applying standard work instructions with step-by-step guides for process confirmation, TEMPO visualizes real-time progress for short interval control, providing instant decision making to maintain compliance to plan.
  • By using TEMPO to plan and execute complex maintenance turnarounds our clients have achieved 50%+ reduction in downtime, giving a 10%+ improvement in fleet availability.
Reduce maintenance backlog by 60%!
  • Unlock valuable maintenance time and use it to reduce chronic backlogs or stubborn deferred defects.
  • Give technicians more time for proactive interventions.
Improve asset reliability by 18%!
  • Enjoy the knock-on benefit of backlog clearance and proactive activities, improving the reliability of your assets.
Increase continuous improvement engagement by 180%!
  • TEMPO’s easy-to-use Concerns and Ideas capture feature engages technicians in driving improvements that help improve turnarounds, reliability, and availability
  • Identify the classic wastes (transport, inventory, motion, waiting, over processing, over production, defect) in relation to your maintenance activities.
  • Expose supply chain, kitting, resourcing, workplace organization, sequencing, tooling, and planning opportunities for review through TEMPO’s powerful reporting feature.
  • Analyze the hour-by-hour compliance to plan with the associated losses incurred throughout the turnaround event.
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