Automotive Manufacturing

Operate at peak performance while addressing the top challenges shared by OEMs and automotive suppliers.
Automotive manufacturing is an intensely competitive business with complex concerns unlike those of any other industry. The drive to protect profitability compounds the pressure for tier suppliers, the supply chain, and OEMs alike, compelling manufacturers to maximize quality and operational efficiency.

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Toward Zero helps you meet automotive industry concerns head-on so your business can achieve the high-performance targets required to satisfy customers, win new business, and do more than operate profitably.

Nearly every company in the automotive sector — car manufacturing, automotive parts manufacturing, commercial vehicle parts manufacturing, and tire manufacturing — faces complex quality and performance demands:

  • Operate at peak performance
  • Boost problem solving capabilities
  • Address customer-specific requirements
  • Navigate complex and redundant quality management systems (QMS) requirements
  • Apply collaborative and effective product development methods and solutions
  • Protect against loss of experience as highly skilled workers retire

Whether you’re poised for the next stage of the performance race, or seeking crisis management to bring quality and operations up to contract standards, we have proven experience, methods, and solutions to meet your goals.

Toward Zero helps you build on what you and the automotive industry has already achieved – some of the highest quality levels in the industry, record vehicle volumes, and a vision to meet ever-increasing quality and performance demands. With us, you can win despite the complex pressures in automotive manufacturing today:

  • Eliminate the merry-go-round of continually addressing the same problems
  • Empower leadership and the workforce to cultivate and achieve a culture of quality
  • Leverage existing IT and new solutions for effective root cause analysis and problem-solving
  • Evaluate and prioritize operational efficiency opportunities
  • Increase problem-solving capabilities to manage, monitor, and respond to quality-related events
  • Standardize and institutionalize processes and systems to meet disparate quality management system (QMS) requirements
  • Apply a Quality 4.0 approach to manage customer expectations and relationships
  • Forge a collaborative partnership between product development functions and manufacturing operations
  • Collect and democratize data from manufacturing equipment and processes to contribute to Design in Quality, Design for Manufacturability and Design for Six Sigma
  • Establish processes and systems to capture and apply tribal knowledge from retiring workforce to ease or eliminate the impact of loss of experience
  • Help you choose the right technologies to serve the business while attracting younger, digitally savvy workers

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Every automotive manufacturing company experiences and responds to industry pressures differently. Toward Zero helps you run operations profitably and position your organization for competitive advantage.

Car and light truck manufacturing, automotive parts manufacturing, commercial vehicle parts manufacturing, and tire manufacturing have vastly different pressures, resources, and capabilities.

Tier 1 Automotive Suppliers

Most Tier 1s worry about the supply chain and their ability to get the right parts and raw materials needed at the right time, in the correct quantities, and at the right price to meet their own CSRs. Adding to the pressure, OEMs have reduced the number of Tier 1 vendors to favor larger, more tech-ready companies with global manufacturing capabilities. That means the typical Tier 1 enjoys a more balanced book of business than other automotive suppliers, but at a steep price. Customer service requirement variations among the many OEMs drive up complexity and cost. While quality is critical to every OEM’s business, unique customer service requirements also contribute to competitive advantage. For Tier 1 suppliers, the complexity associated with OEM CSRs can be quite difficult.

Job Shops

Job shops that supply Tier 1s and Tier 2s might be cash-constrained and lack the resources to implement quality, MES, production scheduling, and other critical solutions they need to meet customer and regulatory requirements. They may also lack the continuous improvement focus needed to keep pace and compete effectively. These automotive manufacturing companies are likely overwhelmed by the complexity of multi-level CSRs and struggle to keep pace with volume and quality demands.

Automotive OEMs

Despite their size and ability to implement modern solutions, even OEMs worry about the implications of not meeting today’s top challenges head on, particularly where less-than-exceptional problem-solving impacts customer expectations and relationships. Focus on the shifting regulatory environment may mean they have to reconfigure the supply chain. A possible shift in the economic climate, shifting brand loyalty, variable supply of used vehicles, and rapidly changing consumer preferences all mean that car makers must do everything possible to protect the brand, respond to demand changes, and ensure profitability.

Can an OEE system help you overcome operational challenges?

  • žš’Reduce planned and unplanned downtime
    Increase throughput
    Improve quality
    Provide quick, easy performance metric
    Create starting point for uncovering reasons for performance loss
    Support continuous improvement
    Rally team members around performance objectives
    Establish common ground for best practice sharing
    Benchmark plant or enterprise performance

Request a OEE value assessment, and we’ll provide you with:

  • Detailed questionnaire specifically designed for your industry
    60-minute consultation with an operations improvement expert to understand your specific needs and environment
    Custom report with value estimates by category, and recommendations for order of priorities
    30-minute consultation with your operations improvement partner to discuss report findings and answer your questions
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Collaborative Decisions