Project Type |
Project Name |
1st Year Savings |
---|---|---|
Warranty | Eliminate shifter knob adhesion failures | $167,000 |
Campaign | Eliminate seat belt ratchet fail to lock | $30,000,000 |
Campaign | Seat Belt inertia lock failure mitigation | $17,000,000 |
Training | Implementation of OEM internal engineering training system | Confidential |
Training | Implementation of OEM supplier quality system training | Confidential |
Service | Improved call center – call resolution time by 27% (improving productivity) | Confidential |
Warranty | Develop effective prob. solv. process | $2,000,000 |
OEE Improvements | Cam bearing equip improvements | Confidential |
Continuous Improvement | Eliminated bumper energy absorption voids | $610,000 |
Supplier Management | Scorecard improvement initiative | Confidential |
Industry 4.0 | Real-time data collection syncronized to equipment, tooling and monitoring system | Confidential |
Service | Improved First-Time job completion rate by 65% through VSM work optimization | Confidential |
Launch | Improved seat assembly fail to achieve torque | $444,000 |
Warranty | Eliminated headlamp cracking/moisture | $400,000 |
Continuous Improvement | Injection molding process optimization | $357,000 |
Training | APQP and Prog. Mgt. new product implementation | Confidential |
Launch | HVAC blower noise reduction | $175,000 |
Service | Improved renewable energy site service efficiency through implementation of standardized work | Confidential |
Launch | Steering shaft binding/noise reduction | $575,000 |
Mistake Proofing | Upgraded robotic equipment and reduced high RPN values | $1,800,000 |
Warranty | Sunroof flushness to roof | $100,000 |
Training | PPAP accuracy and timeliness improvements | Confidential |
IT/ERP | Linked financial and operational metrics to real-time data utilization and reporting | Confidential |
Campaign | Corvette sunroof de-lamination elimination | $1,145,000 |
Campaign | Fuel tank de-lamination elimination | $3,000,000 |
OEE Improvements | Improved casting and forging voids | $1,200,000 |
OEM Asm. Plant | Eliminated door glass binding | $50,000 |
Warranty | Eliminated mirror switch malfunction | $225,000 |
OEE Improvements | Improved rotor and stator generator throughput and quality | Confidential |
Tooling Transfer | Transferred 67 tools in 5 countries | Confidential |
Validation | Eliminated seat belt web payout failure | Confidential |
Validation | Improved body side molding adhesion | $105,000 |
Validation | Reduced SMC hood cracking | $120,000 |
OEE Improvements | Implemented Spare Parts criticality system improved unplanned downtime | $670,000 |
OEE Improvements | Improved wire and cable throughput | Confidential |
Mistake Proofing | Implemented electronically sensored tooling to reduce scrap | $2,100,000 |
Warranty | Improved door beltline seal capacity | $3,300,000 |
Service | Implemented quick reference trouble shooting guides to reduce problem resolution time and improve quality | $550,000 |
Warranty | Improved design and mfg. process of seat belt Center of Gravity mechanism | $67,020,000 |
Launch | BCM connection failures eliminated | Confidential |
Launch | Seat back fail to clamp redesign | $57,000 |
Training | DFMEA/PFMEA/CP implementation and system connection improvements | Confidential |
Lean Mfg | Casting machining optimization | $745,000 |
Supplier Development | Develop new coating technology to PPAP | Confidential |
Warranty | Glass run channel gapping reduction | $3,008,000 |
Warranty | Resolved fuel connector cracking | $7,500,000 |
Warranty | Parking brake wont set improvements | $320,000 |
Warranty | Improved molded door panel warp | $375,000 |
Warranty | Reduced Windshield cracking | $406,000 |
Warranty | Eliminated visor mirror switch failure | $210,000 |
IT/ERP | Transitioned from manual data collection to scanner and equipment auto-collection system | Confidential |
Warranty | Improved power steering pump FTQ | $279,000 |
Lean Mfg | Production scheduling optimization | $857,000 |
Mfg. Plant | Improved drilling operation out of alignment scrap | Confidential |
Mfg. Plant | Eliminated T-Bar hole too large scrap | Confidential |
Mfg. Plant | Improved scrap – poor bobbin retention | Confidential |
Mfg. Plant | Yoke housing damage | $100,000 |
Business Transfer | Facilitated on-time PPAP transfer of 145 tools | Confidential |
Suppy Chain Mgt | Implemented scrap reduction initiative | $2,400,000 |
Validation | Improved label retention (FMVSS) | $100,000 |
Launch | Airbag symmetry visual gap improvement | $67,000 |
Lean Mfg | Improved constraint/productivity-VSM analysis for frt. row seating | $822,000 |
Warranty | ABS circuit board failure elimination | $312,000 |
Validation | Eliminated airbag testing equipment failures | Confidential |
Asm. Plant | Reduced bumper install installation sequencing time | $110,000 |
Mfg. Plant | Improved powertrain main shaft OD scrap | $147,000 |
Mfg. Plant | Improved power steering casting machining scrap | $89,000 |
Mfg. Plant | Front rotor flatness scrap reduction | $289,000 |
Warranty | ABS valve FTQ improvements | $1,450,000 |
Training | Implemented an effective problem resolution process | Confidential |
Validation | Brake deceleration fluctuation reduction | $225,000 |
Mfg. Plant | Improved wave solder failures | $172,000 |
Warranty | Pressure sensor failure elimination | $348,000 |
OEM Launch | Improved power steering noise | $480,000 |
Warranty | Drastically improved door lock freeze (across models) | $2,000,000 |
Training | Implemented MSA & SPC to improve product & process capability | Confidential |
Mfg Plant | Eliminate airbag canister leaks | $225,000 |
OEE Improvements | Stamping mistake proofing processing improvements | $450,00 |
Warranty | Eliminate mirror switch failure | $316,000 |
Validation | Eliminate OEM mirror switch testing failure | $145,000 |
Warranty | Airbag wiring failure elimination | Confidential |
Warranty | Airbag canister leak tester failure elimination | Confidential |
Warranty | HVAC control malfunction scrap elimination | $166,000 |
Warranty | Reduction in keypad failures | $48,000 |
Warranty | Eliminate brake caliper testing leak | $406,000 |
Validation | Steering gear angularity failure reduction | Confidential |
Mfg. Plant | Improve brake drum machining scrap | Confidential |
Warranty | Random door locking software “glitch” elimination | $710,000 |
Asm. Plant | Reduced suspension bushing assembly scrap | $100,000 |
Asm. Plant | Reduced caliper equipment assembly scrap | $486,000 |
Launch | Eliminated front headlamp assembly scrap | $188,000 |
Warranty | Headlamp water intrusion assembly scrap elimination | $896,000 |
Warranty | Reduction of rear seat frame rusting | $92,000 |
Mfg. Plant | Reduction of powertrain housing component machining scrap | $2,700,000 |
Mfg. Plant | Injection molding scrap elimination through DOE optimization | $1,100,000 |
Past ProjectsMichigan Business Transformation Consultant2018-01-17T17:31:29+00:00