The Challenge
A $1B turnaround, a misaligned CI group
High-segment vehicle programs were carrying a $1B sales turnaround, and the North American Continuous Improvement group wasn't aligned to the company's goals. The supplier needed a CI organization that could both deliver savings and sustain them — across multiple plants on two continents.
The Approach
Build the CI organization, track every dollar
- ▸Restructure and align the North American Continuous Improvement group with company Goals & Objectives
- ▸Lead and coach 10 global operations through the turnaround
- ▸Run disciplined multi-site productivity drives — weekly report-outs, R-Y-G status, and confirmed-vs-projected tracking across three plants in North America and South Africa
- ▸Attack cost through line-balance kaizens, assembly-line consolidation, and packaging and transport redesign
The Outcome
Measurable results
- ✔$52M in North American CI savings in 2017
- ✔A $1B sales turnaround stabilized, generating $60M EBITA on high-segment vehicles
- ✔A self-sustaining CI organization tracking every initiative confirmed vs. projected