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Practical example

Transformation of a supplier from a non-automotive sector into an automotive mass-production manufacturer

We supported a renowned manufacturer in the industrial and consumer goods sector through its transformation into an automotive supplier. Our goal was to ensure production readiness and the successful initial product-process maturity for an innovative component (charging socket).

Background

The client, an experienced player in other industries, had no experience in the automotive sector. This led to challenges such as a lack of understanding of automotive requirements, insufficient expertise, and inadequate organizational and project structures. The situation was exacerbated by an ineffective project PMO and a lack of sustainability in problem-solving.

Specific task

Our assignment involved conducting an assessment, planning and prioritizing necessary steps, and establishing a task force structure. We were tasked with coaching the client on tracking and applying automotive methodologies, establishing an efficient change management process, and supporting the project management team in communicating with the automotive OEM.

KBC's Approach

We implemented a comprehensive coaching program for automotive methodologies such as FMEA, Special Characteristics, 8D, and MUP. We also established a robust change management process for technical and commercial aspects. Our team supported project management in reporting and communicating with the customer and ensured efficient escalation. We began our work three months prior to the planned production process and product release (PPF).

A woman with brown, medium-length hair and brown eyes, smiling, wearing a white blouse and black pants, standing with her hands on her hips
A woman with brown, medium-length hair and brown eyes, smiling, wearing a white blouse and black pants, standing with her hands on her hips
Larissa Fahrmeier
Director

Impact achieved

Despite significant time pressure, the PPF was achieved on schedule. The escalation level for the supplier we were supporting was reduced. We raised the customer’s long-term awareness of the automotive OEM’s requirements and embedded them within the organization. Of 86 audit criteria, only 5 were assessed with minor deviations, underscoring the success of our approach. Overall, the customer successfully transformed into a full-fledged automotive series supplier for an innovative component.