The supplier was preparing for a program ramp that introduced greater model complexity, frequent sequence changes, and tighter delivery windows. Manual handoffs and inconsistent staffing made it difficult to maintain a predictable flow of line-ready components.
Sequenced racks were sometimes completed too early, too late, or in the wrong order. The resulting variability increased buffer requirements, created costly expediting, and raised the risk of a line-down event. The supplier needed an operating partner that could stabilize execution without adding management burden to its internal team.
OpTech began with an on-site assessment of release signals, sequencing workflows, staffing requirements, rack movement, and delivery routes. The team then developed standard work for each step—from order receipt and pick confirmation through final sequence verification and line-side delivery.
A dedicated managed-labor team was deployed across the required shifts, supported by trained leads and flexible backup coverage. Scan-based verification and documented quality gates were introduced to catch sequence errors before racks left the staging area. OpTech also aligned delivery cadence with OEM production windows and established clear escalation procedures for schedule changes, shortages, and other exceptions.
Daily performance reviews tracked delivery timing, sequence accuracy, labor coverage, and open issues. This gave the supplier greater operational visibility while allowing OpTech to adjust staffing and workflows as production demand changed.
Within the first 90 days, delivery variance decreased from approximately ±22 minutes to ±7 minutes—a 68% reduction. On-time deliveries reached 99.4%, while sequence accuracy remained above 99.7%.
The more predictable delivery cadence allowed the supplier to reduce emergency expedites and operate with less protective inventory near the line. Flexible staffing also helped the operation absorb model-mix changes and short-notice volume increases without disrupting scheduled deliveries.
During the first six months of the program, the operation recorded no line-down events attributable to sequencing or delivery performance. OpTech continued managing the day-to-day workforce, verification process, and performance reporting, giving the client a stable sequencing operation that could scale with the OEM’s production schedule.
