Initial situation:
- Production delays due to backlog of 130,000+ parts threatened OEM supply.
- Escalation to Q-Help Level 3 – highest OEM quality escalation level.
- Key issues: severe know-how loss, leadership turnover, shareholder changes, and low efficiency.
Our approach:
- 80% backlog reduction via optimized scheduling and logistics reorganization.
- +18% OEE through machine optimization and stabilized processes.
- Quality transformation: 70% fewer customer complaints, 90% PR/PS cases resolved.
- 30+ key personnel (setters, inspectors, team leads) hired and trained.
- Lean workflows and digital tracking introduced for real-time monitoring.
Results:
- Delivery performance improved from 20% to 93%.
- €1.8M annual cost savings through process and waste optimization.
- Reaction time to issues reduced by 50%.
- Long-term stability secured – escalation fully de-escalated.
Conclusion:
Rapid recovery, measurable impact – sustainable supplier performance reestablished.
