Crisis Management
Customer – Tier 1 Supplier
- OT Reduction better than forecast within 2 weeks
- Inventory accuracy improvement from 72% to 96%
- Labor headcount reduction from 761 to 598
CASE STUDIES
Our Client’s Successes
Product Launch
Customer – Tier 1 & Tier 2 Supplier
Plant – 750k sq ft with 1,850 team members
Annual Plant Revenue – $450M
Results
- Spectrum was able to achieve all Customer Milestones, secure and launch with zero mis-deliveries, and one minor quality incident
- Eliminated Delivery and OEM Shutdown risk
- Spectrum recruited and installed the new GM and made a smooth 90-day transition to ensure success
- Spectrum installed systems and disciplines in the organization gave sustainable stability and profitability after Spectrum exited the engagement
- Payback for investment in Spectrum < 90 days
- Spectrum has been asked back to support on additional projects as needed
Problem
- The team was not ready for 3 high-volume programs all launching within 3 months from one another
- The new product launches were at high risk for potential SOP miss, delivery miss, and OEM shutdown
Solution Approach
- Spectrum was engaged to assess the situation and develop a containment plan to secure the SOPs for achieving Quality & Delivery goals.
- Spectrum assumed the General Manager position, Production Manager position, and a Data Analyst position.
- It was quickly determined that the immediate concerns were coming from late and inadequate program development; not enough installed capacity; workforce engagement problems and lack of skilled engineers and maintenance personnel.
- The GM took complete accountability for Sales, Program Management, and Manufacturing.
- A review and implementation of proper Structure and Personnel assessments led to a decentralized organization, recruitment of proper talent, and dismissal of non-value added overhead.