+9K
Vehicles repaired within six months, minimizing customer impact
Rapid Supply Chain Recovery Through Command Center Management: Restoring Production Stability and Supplier Performance in Commercial Vehicle Manufacturing
Industry: Automotive and Commercial Vehicles
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: Supply Chain
Our Client
A leading commercial vehicle manufacturer operating multiple North American assembly plants, facing severe supply disruptions during the launch of a new vehicle model.
The Challenge
A major supply chain breakdown during a new model launch led to widespread production delays and customer dissatisfaction:
- Over 3,500 vehicles taken offline in a single quarter due to supplier failures.
- Severe shortages from 20 key suppliers, halting assembly operations.
- POA performance and first-pass yield dropped to 30%.
- Inefficient logistics and poor Point of Use (POU) material handling created further disruption.
- Conflicting priorities across purchasing, supplier development, and production functions delayed recovery efforts.
Real Results Achieved Together
Through a Command Center-driven recovery program, EFESO helped the client stabilize production, recover supplier performance, and restore customer confidence. The initiative led to significant improvement in POA performance, a marked reduction in red-tagging across all plants, and a fully cleared backlog that restored on-time customer deliveries and production flow stability.
55%
Increase in production output at key suppliers
Transformation Impact
- Established a coordinated crisis management structure integrating suppliers, logistics, and production.
- Standardized work processes across supplier recovery and vehicle repair operations.
- Enhanced flow efficiency through redesigned work cells and optimized material handling.
- Aligned cross-functional teams around shared KPIs, improving decision speed and accountability.
- Restored operational confidence and customer satisfaction through sustained delivery performance.
Our Approach
EFESO implemented a Command Center framework to manage crisis recovery, restore supply chain flow, and embed sustainable practices.
Establishing a Centralized Crisis Management Structure
- Created a main Command Center at U.S. headquarters with satellite units at key Mexico and U.S. plants.
- Deployed on-site teams at seven critical suppliers to coordinate recovery efforts.
Executing Rapid Recovery Solutions
- Introduced Dynamic Work Design boards for real-time visibility and rapid intervention.
- Formed cross-functional virtual teams integrating purchasing, logistics, and manufacturing.
- Conducted root cause analyses to eliminate recurring quality and delivery issues.
- Established a dedicated repair line to standardize post-assembly vehicle rework.
Optimizing for Sustainable Performance
- Designed standard work processes for suppliers, logistics, and repair operations.
- Redesigned work cells and job methods to boost flow efficiency and capacity.
- Identified and eliminated logistics bottlenecks to improve throughput and coordination.
- Introduced a structured production cadence to synchronize component delivery with demand.
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Facing Similar Challenges?
- Supplier performance or delivery issues affecting production flow.
- Recover from large-scale backlogs and stabilize operations quickly.
- Embed structured crisis management and sustainable performance systems.
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