Improve overall labor hours/car productivity 30%+ at auto assembly plant.
Plant was severely overstaffed for the level of production, based on reliable benchmark data for USA auto assembly plants
Absence of assembly line quality control was driving 300 extra heads (30% of the total reduction) in final line rework
Ineffective line balancing of the assembly work stations was driving another 400 extra heads along the vehicle assembly line
Excess managerial staffing and delayering was driving another 300 extra heads at the site
Total reduced workforce was 1000, out of the beginning total of 4000.
Changes implemented in less than 1 year with improved quality and highest profitability ever achieved
Plant reached top quartile in benchmark productivity reports