Bain uses cookies to improve functionality and performance of this site. More information can be found in our Privacy Policy. By continuing to browse this site, you consent to the use of cookies.

Case Study

Streamlining engine assembly boosts ouput

AutoCo, a major automotive manufacturer, was extremely profitable, but customer demand for vehicles exceeded existing capacity. It charged Bain with improving productivity on the main assembly line to produce five more engines per hour. Our teams deconstructed the manufacturing process to uncover the highest priority drivers of cycle time and the resulting process improvements doubled the client's original cycle time reduction goal.

  • min read

At a Glance

  • 2x the client's original cycle time reduction goal

The Full Story

The Situation

AutoCo* is a major automotive manufacturer whose large vehicle group is extremely profitable, but customer demand for these vehicles exceeds existing capacity

AutoCo's large-vehicle production is constrained by engine output. Executives want to increase the rate of engine production by five jobs per hour.

Plant management determined that XYZ Assembly* was the primary obstacle to achieving the engine production necessary for the target number of vehicles.

As part of a full potential manufacturing improvement program, AutoCo charged the Bain team with:

  • Improving productivity at the bottleneck machine on the main assembly line
  • Improving the yield of the subassembly department feeding the bottleneck machine
  • Finding five more engines per hour (JPH) on the XYZ Assembly and on the mainline station it feeds

 

Our Approach

For each machine, Bain deconstructed the manufacturing process to uncover the highest priority drivers of cycle time.

 

Our Recommendations

The team focused on a 1.5 second-per-cycle overrun that occurred 75 percent of the time and yielded an 11 JPH loss.

 

The Results

Bain nearly doubled the client's original cycle time reduction goal and identified fuller upside potential in the assembly.

 

* We take our clients' confidentiality seriously. While we've changed their names, the results are real. 

Want to continue the conversation?

We help global leaders with their organization's most critical issues and opportunities. Together, we create enduring change and results.