Case Study

"This whole build event wouldn't be possible without QR_!"

Program Manager, large OEM

Improving part availability on MRD for a 480-vehicle prototype fleet to avoid costly testing, tooling, supply chain, and manufacturing delays.

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Outcomes

Parts available at MRD

75%

>95%

Material cost savings

$21M

Incorrect build BoMs

21%

0.3%

Average vehicle delivery delay

21 days

-2 days

Engagement cost

£878k

A major North American OEM was averaging only 75% part availability on material required date for their prototype builds, leading to late vehicle testing and delays to production timing. QR_ turned this around with a single engagement on a major new vehicle program covering 6,500 end items and a 480-vehicle prototype fleet, deploying both consulting and tactical support teams alongside the client.

Consulting

Established regular governance to find program bottlenecks and priority areas
Built data visualisation for part-level prioritisation, replacing siloed offline data sets with a single plan
Created a Part-level Cost Attack tool and process to run material cost negotiations — reusable on future programs
Built a Plant Capacity tool to optimise build schedule, surface risks, and drive action

Tactical support

Lead-time analysis for program prioritisation and at-risk part ordering
Supplier event for 250 suppliers to confirm parts orders, share processes, and resolve issues on the day
BoM validation 'at elbow' with engineering, including authoring and correction
Change management accelerated from 15 days average per change down to 3 days
Ongoing supplier engagement built around openness and continual communication — 'Hope is not a strategy'
At-build launch support: build prioritisation, issue resolution, rapid change management

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