+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.
Automotive and Commercial Vehicles
Manufacturing
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.
Related Services
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
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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