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A high complexity product caused quality, cost and productivity issues for this prestige vehicle manufacturer ahead of the launch of a new car model. The client sought an ambitious programme to get the project back on track...
This major Original Equipment Manufacturer produces vehicles with a large number of customer facing options and extras; a high complexity product with a particularly high degree of variation. Facing issues with quality, cost and productivity (needing to effectively balance cycle times to customer demand), the manufacturer sought to put an ambitious programme into action. This would deliver what they called a ‘Stable TAKT’ program across its entire UK assembly hall ahead of the launch of a new car model.
The production line had a low level of efficiency as, in order to build any vehicle specification at any time and in any quantity, more team members were deployed. However, these additional people could often be left idle.
The lack of a balanced workload also impacted quality. More staff were required to check and inspect vehicles at key points and this further damaged efficiency.
In order to deliver the project, the manufacturer needed support from an experienced organisation that could bring the required expertise.
The potential partner needed to be able to engage with management and production teams in a practical way, as well as transfer capability so that improvements could be sustained and built on for the future.
Unipart were selected as many of the requirements are key features of Unipart’s world-class body of knowledge: ‘The Unipart Way’, along with manufacturing expertise, coaches skilled in capability transfer and a track record of delivering sustainable change.
The Unipart Team worked alongside employees from our client to develop their ‘Stable TAKT’ model and integrate this into their production system. This would involve:
The project was successful to the degree that the global manufacturer saw fit to roll out the changes, developed as outputs of the Stable TAKT project within this production facility, as best practice in its global production system.