Propulsion Transmissions: New Program Launch Leadership


Deploy highly skilled, highly experienced supplemental labor/management resources for a major Tier I North America automotive supplier of propulsion transmissions, during critical and troubled new program launch.

Results included:

  • Implemented new constraint management and data analysis system to drive continuous improvement process.
  • Developed Tier I’s engineering team and budget; implemented best practice project management processes.
  • Improved JPH from 3.7 to 7.5 toward a capability of 10 JPH over a five-month period reaching 80% of capacity.
  • Improved constraint equipment cycle time from a weekly high of 428 seconds to on average target rate of 300 seconds.



Redirected troubled launch; Implemented new constraint management & data analysis system; Improved JPH and equipment cycle time.

Our Approach

  • PHASE I: Managed the disorder. Stabilized current operations. Defined and outlined Plan of Attack.
  • PHASE 2: Modified and installed new processes/systems. Developed the engineering team. Set-up data throughput improvement system.
  • PHASE 3: Developed new calendar year engineering budget, headcount and project plans. Standardized and documented new processes. Created leadership transition plan for new Engineering Director.


  • Lack of experienced leadership and resources at Tier I Supplier facility to manage complex new program launch.
  • Customer (Automotive OEM), recognizing overwhelming operational issues, deployed 30+ supplemental technical resources to focus on operations due to urgency and priority for a new vehicle launch.
  • Multiple issues - related to equipment reliability and process sustainability - impacted throughput and did not meet stated build capacity.
  • Jobs Per Hour (JPH) were significantly below ramp up targets, creating shortfalls to weekly build schedule shipments and requiring costly Non-Scheduled Overtime (NOT).
  • Lack of data collection and analysis systems to drive throughput improvement process.
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Supporting Materials