Lighthouse Project

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

“Some years ago my team and I worked successfully in a project with Lean Coaching in a production environment. Two years later this success was even acknowledged with an award by a leading business magazine.”
Martin Rentschler
Head of Production Support and Operational Services

Problem

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

Lighthouse Project

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

“Some years ago my team and I worked successfully in a project with Lean Coaching in a production environment. Two years later this success was even acknowledged with an award by a leading business magazine.”
Martin Rentschler
Head of Production Support and Operational Services

Problem

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