Case Studies

Improved Operational Efficiency and Output Resulting in Annual Savings of $3.1M

Client: Major OEM
Fleet Size:500 vehicles

Involved Shop Operations with 90 Team Members Supporting Vehicle Builds


  • On-time delivery improved from 80% to 99%
  • As efficiency improved, overtime was reduced to completion of work on straight time; saving $3.1M annually
  • As costs were reduced and performance improved, additional work continues to be sent to our shop for completion


  • No line of sight to upcoming work resulting in a lack of production planning
  • Lack of urgency to complete vehicle builds
  • Communication to team members was inconsistent
  • Extra vehicles maintained in the fleet due to delayed turnaround of vehicles

How we did it:

  • Implemented daily production board meetings with shop leaders
  • Drove accountability to all team members for task completion
  • Established monthly key performance indicators (KPIs) to measure improvements and identified barriers to continuous improvement. Removed barriers allowing performance to improve to the next level
  • Regular meetings with all clients to gather the line of sight for upcoming work. Drove planning requirements to our clients, improving both their process and ours