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Volume Recovery & Cost Reduction

BorgWarner

Improved output by 10x and reduced scrap cost by more than 50%.

Challenge

  • New products were not hitting contractual volumes with OEMs, driving increased cost and revenue loss.


Actions

  • Deployed fast response team to roll out standardized problem solving, daily standard work, 80/20 Pareto analysis, and other lean tools.

  • Coached engineers and technicians on root cause analysis and corrective actions.

  • Applied relentless PDCA in a controlled environment.


Results

  • Improved output by 10x in less than 12 months.

  • Reduced scrap cost by more than 50%.

  • Restored delivery reliability for critical customer programs.

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