Case Study: Calsonic Kansei – Automotive Injection Moulding Improvements

Quality & Delivery Improvements – 1st tier Injection Moulded & Painted Parts

Provision of skilled senior interim to resolve capacity and quality issues which impacted on deliveries.

Problem statement:

Calsonic Kansei, a multinational Automotive Tier 1 company, had capacity issues that were causing customer delivery concerns & incurring special transport charges.

What we did:

  • Provided a skilled Engineering Project Manager  for an improvement project within the injection moulding facility. Following the success above, we took control of the under performing painting facility within an Automotive Tier 1 supplier installing an interim Paint Plant Manager. 
  • Worked closely within MP&L department and implemented back to basics approach to product scheduling and monitoring with full BoM review in relation to MP&L. This enabled buffer management with strategic inventory reduction via level scheduling and changeover reduction. 

The project benefits:

  • Improved process monitoring and capabilities, implemented a self managed team approach.
  • Reduced Mould Facility downtime by 60% by employing QCD methodologies and measures.
  • Reduced scrap from 40% to 2.4% in four months.
  • Reduced overtime costs by shift realignments and improved PPM programs.
  • Eradicated Special Transport requirements resulting in £69K per month saving.
  • Increased ‘Right First Time’ by 20% in first 6 wks.
  • Implemented headcount reduction program achieving budget within 4 months

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calsonic kansei

Service: Business Improvement