Initial situation:
- Outbreak of war in Ukraine forced immediate production stop at key Tier-1 supplier site.
- Supply of premium leather seat covers for flagship vehicle program critically endangered.
- Immediate risk of line stops at OEM assembly plants due to lack of alternative capacity.
Our approach:
- Developed and led a fast-track relocation program to alternative sites in Poland and Southeast Asia.
- Managed transport and integration of highly sensitive sewing and perforation tools across borders.
- Recruited, trained, and certified new production teams; prepared site infrastructure and layouts.
- Coordinated with OEM for emergency approvals, from first samples to full PPAP releases.
- Installed daily war-room communication with all stakeholders to steer production, quality, and supply.
Results:
- Relocation of production across three countries completed within weeks.
- Achieved ramp-up to ~450–500 seat covers/day across all sites, restoring full delivery capability.
- Prevented OEM assembly line shutdowns and secured continuity of premium vehicle production.
- Established dual-sourcing setup to mitigate future geopolitical risks.
Conclusion:
Supply chain rescued under extreme conditions – global production resilience ensured.
