SUCCESS STORY
50% production increase within 6 months
Global OEM:
Restoring Material Availability
Operating model transformation enabled rapid production gains
Outcomes
50% More Production
Output increased within six months
50% Less Inventory
Stock levels reduced by half
New Operating Model
Transitioned to a scalable, repeatable approach
BACKGROUND
A global rail OEM with a major UK manufacturing site supplying rolling stock to transport networks worldwide faced severe disruption.
Material shortages and unreliable availability data were constraining output and undermining customer confidence.
the challenge
The client needed to overcome persistent production delays caused by material shortages, restore confidence in material availability forecasts, and enable a rapid production ramp-up to meet growing demand.
SOLUTION
4C worked with the OEM’s leadership and operations team to deliver a multi-faceted programme of operating model change, process discipline, and supplier management.
- Redesigned operating model with structured process improvements and change management
- Established supplier review cadence to proactively identify and resolve delivery issues
- Created a ‘Red Book’ with priority processes, KPIs, and procedures for operational teams during transition
- Implemented data analytics and control tower governance to capture, escalate, and report material availability issues
- Optimised MRP parameters to improve material planning
- Embedded a continuous improvement programme for sustained performance