Initial situation:
- Tier-1 supplier engaged T.A.S. force due to critical supply risks from Tier-2 in Turkey.
- Tier-2 announced exit from automotive business – full relocation of tools was imminent.
- Challenges: quality issues, missing production planning, communication gaps, and high air freight costs to OEMs.
Our approach:
- On-site deployment to manage production, complaints, and relocation readiness.
- Introduced structured problem-solving & complaint tracking.
- Defined and monitored safety stock levels to ensure coverage.
- Restored communication flow and daily decision-making between Tier-1 and Tier-2.
- Identified capacity limits and established clear production planning logic.
Results:
- Quality complaints reduced from 16 to 2 (D6 status) in 9 weeks.
- Safety stock built up from 0 to 65,000 pcs – relocation-ready buffer established.
- Air freight to OEMs fully stopped – standard delivery re-enabled.
- OEM supply secured without disruption.
Conclusion:
Crisis averted – Tier-2 stabilized, Tier-1 relieved, OEM line stops prevented.
