CASE STUDY
Production recovery and performance stabilization at a Tier-1 interiors supplier through on-site PMO leadership
Client Description
- Tier-1 automotive interiors manufacturer with multiple EU /NAF plants supplying seat frames to OEMs
- High-volume facility with recurring throughput and backlog issues requiring external PMO intervention
Key Challenges
- Chronic delivery backlogs disrupting OEM production continuity.
- Low OEE and inconsistent governance driven by poor scheduling, maintenance, and oversight
Approach
- Deployed an on-site Ambe Program Manager (PMO) to lead production stabilization and performance recovery.
- Introduced a structured governance model (“mini-plants”) with hourly boards, daily area meetings, and KPI-based escalation.
- Conducted rapid benchmark assessment identifying >150 gaps; consolidated into 23 project charters across
- Logistics, Maintenance, Production, and CIP.
- Implemented task force workstreams, visual management tools, and standardized OEE/downtime reporting.
- Created a plant-wide roadmap targeting 85% OEE and zero backlog over a 26-week horizon.
Results
- Stabilized production and restored delivery continuity to OEM
- Improved plant governance and accountability through daily performance tracking.
- Launched sustainable improvement system via cross-functional task force ownership.
85% OEE1
target achieved on multiple lines with sustained throughput plus safety stock targets fulfilled
>150Gaps
Consolidated into actionable roadmap and 23 workstream project charters.
1 Production Plan Capacity
