Transforming Manufacturing Performance Through People and Processes
We partnered with an automotive interiors manufacturer to develop a culture of production excellence to meet rising client demand.
Key impacts
11:1 ROI
Productivity increase over 200%
€8 million annualised savings
The challenge: Transform operational performance capabilities to meet critical client demand
Our client, a leading automotive interiors manufacturer, was facing multiple production challenges across several plant locations. One of the priority areas of focus centred upon a critical new product launch programme requiring a rapid turnaround in performance
Customer demand was set to increase exponentially from 120 units to 380 units daily to ensure a successful new model launch. However, operational inefficiencies had created a growing backlog of 1,800 units, whilst scrap and rework rates were also directly impacting upon quality and productivity.
Our immediate objective was to analyse and identify the necessary actions required to achieve an effective turnaround in performance, establish an operating environment that would sustain such a performance breakthrough with sustainable outputs meeting customer demand, whilst reducing waste, improving quality & improving productivity.
The solution: Establish an effective operating environment centered upon people, processes & performance
We undertook a comprehensive analysis of the company’s operational performance, operating systems, processes, leadership approach, team working practices and culture. We developed an improvement strategy and tactical improvement plan for effective deployment, with the full engagement of plant leadership and responsible teams.
We worked hand in hand with operational leaders and functional teams to develop, implement and coach tactical improvement roadmaps while embedding the core processes, system standards, and leadership behaviours necessary to drive performance improvements.
With production and operational stability improving, our approach focused upon continual mentoring, coaching & confirmation in the required process, leadership, and behavioural standards essential for sustaining elevated performance. This equipped leaders and teams with the knowledge and practical skills needed to succeed.
The implementation: How we embedded sustained performance breakthroughs
We focused on empowering people to drive and achieve operational performance improvements. This included implementing structured initiatives designed to transform processes, leadership behaviours and operational efficiency such as:
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By optimising physical setup and material flow we streamlined production, reduced inefficiencies, and increased throughput.
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Real-time data and a drumbeat of hourly checks provided clear accountability, allowing teams to proactively address issues and drive measurable improvements. This was supported by project improvement boards detailing what was required across quality, maintenance, logistics and operations.
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Hands-on coaching to function leads and team managers equipped them with the skills, behaviours, and problem-solving capabilities needed to sustain high-performance standards.
Our approach developed the confidence of leaders to embrace new ways of working and created engaged teams that collaborated daily to drive operational and business improvements. By aligning teams through shared knowledge and a commitment to agreed goals, we developed trust, ownership and accountability.
Throughout the project we challenged the status quo across operations, logistics, quality, and maintenance. This enabled us to introduce robust systems that eliminated inefficiencies and establish a culture of continuous improvement that delivers long-term performance gains.
The results: Significant ROI in a high-performing manufacturing environment
Establishing a culture that drives tangible performance gains has resulted in greater productivity and lower costs, transforming the manufacturing facility performance outlook.
Our transformation strategy delivered:
Output increased from 120 to 410 units per day, surpassing initial targets
€8million annualised savings achieved
Premium freight costs eliminated
1,800-unit backlog cleared
11: 1 return on investment
Following the turnaround programme outcomes achieved, the operational excellence tools, principles and standards were subsequently implemented and rolled out across other production sites, led internally by senior leaders and supported by Spitfire coaches, and delivering further significant and measured value within the business.
Get in touch to understand how our approach can help you to transform your business.