$5 Billion Automotive Component Manufacturer of Passenger Restraints

• A European subcontractor to this large Tier One automotive suppler was experiencing unacceptably high rates of rejects on a key component for a major new product line
• Test methods for production acceptance were flawed
• Production was behind schedule

• BBK secured approval to modify the production test method
• Raw material formulations were altered to improve performance and reduce rejects
• Production constraints were identified and eliminated not only at this Company but also within its supply chain
• Production Control & Logistics (PC&L) and production scheduling systems were improved and monitored

• Rejects were reduced by over 87% (from over 15% to less than 2%)
• Production Part Approval Process (PPAP) was achieved
• Production capacity was increased
• Supply chain production at the Tier Two and Three suppliers was synchronized
• OEM production was protected from any shortage