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1st Tier Automotive – Case Study 2

1st Tier Automotive Lean Logistics


Logistics are often an afterthought for many businesses, whereas the Lean methodology for success has shown that putting Logistics first in the value system can often transform a company.

Putting Lean Logistical Practices in place can help to improve line stops, inventory turns, materials management, and work-in-progress.

Our Lean consultants have repeatedly helped companies move from just-in-case inventory management to dynamic pull systems with levelled production and Kanban systems suited to their environment.


1st Tier Automotive


Eliminate chronic material shortages for a key sequencing plant with turnover in excess of £1bn


  • Materials assessment
  • Logistics diagnostic


  • Introduce Lean logistics provider to optimise routes across Europe
  • Establish supermarket and line-side delivery based on pull, level scheduling of product, and the de-activation of ERP launches
  • Plan per part mapping to improve bill of material accuracy
  • Elimination of high bay storage


  • £12m one-off inventory saving
  • Line stoppages due to material supply reduced to zero
  • Line delivery to OTIF improved by 46%
  • 100% of material controlled by pull systems within an 8 week production horizon

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.

Book an appointment with a Lean consultant at a time that suits you

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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