+20%
Total productivity increase
Lean Transformation Boosts Productivity 20% in Luxury Automotive
A luxury automotive manufacturer faced significant challenges as it attempted to ramp up a second vehicle series, introduce a third on the same assembly line, and absorb a rapid volume increase. EFESO deployed a structured, multi-phase Lean Transformation that increased throughput, stabilized quality, and improved productivity across all series.
Industry: Automotive and Commercial Vehicles
Service: Manufacturing
Service: Operations Strategy and Transformation
Our Client
A premium automotive manufacturer producing high-variant luxury vehicles with an established Lean Production System.
The Challenge
The manufacturer needed to stabilize and accelerate production while managing increasing complexity across multiple vehicle series:
- Ramp-up issues for the second vehicle series entering the production line
- Introduction of a third series on the same assembly line
- Doubling of production volumes in only a few months
- Need to improve productivity, stabilize quality, and rebalance processes across high-variant models
Real Results Achieved Together
EFESO’s structured implementation, combining KPI-focused execution, process redesign workshops, and deep waste analysis—unlocked major performance gains across productivity, volume, and quality.
+85%
Manufacturing volume growth
+30%
Improvement in Right First Time quality KPI
Transformation Impact
- 15 to 25 percent productivity increase after only 8 weeks
- 20 percent total productivity at the plant confirmed after 5 months
- 30 percent reduction in the assembly line cycle
- Reduction of rework effort through quality control loop improvement
- Focused Lean Transformation along the entire assembly line with 5 parallel projects
- Smooth introduction of pre-series vehicles into production
Our Approach
EFESO supported the automotive client by:
- Taking a structured and parallel approach for Lean Transformation with early manager involvement including:
- 3-week analysis and concept phases
- 6-week implementation phase
- 8-week light support phase
- Ensuring there was focus on KPIs per division right from the start
- Hours Per Unit (HPU), Right First Time (RFT), Defects Per Vehicle (DPV)
- Recording comprehensive video of process sequences and joint waste analysis for 2 series model variants
- Improving process and design of new series in the form of 3P (Pre-Production-Planning)-light workshops
- Consolidating Yamazumi boards of all processes and parallel line balancing of the three series
Overall, a targeted implementation with prioritization of metrics.
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Ready to Transform Your Production While Scaling Operations?
- Achieve breakthrough productivity gains while managing complex multi-series ramp-ups
- Stop struggling with quality issues and inefficiencies during high-growth phases
- Join leading manufacturers who’ve successfully scaled operations without compromising excellence
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