Daimler

Lighthouse Project Case Study

Daimler Truck is one of the world’s largest commercial vehicle manufacturers, with over 35 main locations worldwide & approximately 100,000 employees.

PROBLEM

Daimler Cleveland plant was a burning platform, fertile ground and had a willingness to change. All KPI’s were in a critical condition

SOLUTION

  • Shop Floor Management
  • Visualization projects
  • Quality projects
  • Logistic projects
  • Jishuken projects
  • Toyota Sensei approach

RESULTS

  • Year/year savings of $30 million
  • ROI – X > 7:1
  • OHSA Recordable rate improved by 46%
  • DPU improved by 62%
  • HPV improved by 24%
  • On Hand Inventory reduced by 50%
  • Employee suggestions improved by 37%
  • Quarter after Daimler Trucks own scorecard showed Cleveland on Target in all KPI except cost, but improving