MAHLE

Lean Transformation Case Study

MAHLE is a leading international development partner and supplier to the automotive industry as well as a pioneer for the mobility of the future. They are a global tier 1 high volume supplier of pistons, rings, camshafts, bushings and bearings for the automotive vehicle market.

PROBLEM

Lean Coaching was engaged in order to provide a program that addressed biggest MAHLE’s issues and challenges, focused mainly on Lean Transformation and ensuring production stability, as well as building essential competencies within the organization, for the sustainability of implementations and results to long term.

SOLUTION

  • Deep dive diagnosis across entire organization
  • Immediate containments to problem areas
  • Lighthouse program to ensure transformation
  • Visibility of activities throughout plant and at stakeholders
  • Develop internal change agents to drive performance
  • Focus on lean oriented mindset over all leadership levels through coaching Sensei approach (I do – we do – you do)
  • Set direction and get consensus through Hoshin Kanri

RESULTS

  • Scrap reduction by 31%
  • WIP reduction by 20%
  • Productivity increase by 13%
  • Standard work and process confirmations in place
  • Shop floor management including Go & See and problem solving displayed on information centres at all levels
  • Standards linked to MPS
  • Lean awareness improvement at all levels
  • Leadership lean skills and behaviour improvement by coaching
  • Manufacturing diary implementation