1.Understanding of current situation (GEMBA):

•Process Control Plan was not followed

•Shop Floor Management BASICS were not followed

• Management Recovery Action Plan had 8-months overdue actions

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2.Critical Success Factors Implementation:

•War Room/OBEYA implementation 

•Specific roles for every team member from Operators, Supervisors and Engineers to Managers

•Specific GOAL and KPIs defined and communicated

•Specific Escalation Rules

•Daily review of execution level in the War Room

•Execute and deliver every commitment promised to Customers and advise in advance of any deviation

•GAP Assessment performed vs TS and Customer Requirements

•Specific Improvement Action Plan defined based on the GAP Assessment

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3.Accomplishments:

•Achieved de-escalation with all customers within a year

•Maintained Ford Q1

•Operations Returned to BASICS

•Great Participation of almost all levels in all areas: Operators, Supervisors, Engineers, Managers and Directors

•Zero Non-Conformances observed during Customer Process Audits