Project
Automotive
Year
2026
Battery module line
A new battery module line brought to rate six weeks sooner than planned.
Headline result
−38%
Ramp-up time vs. plan
Ramp-up
16 wk
10 wk
−38%
Scrap rate
4.1%
1.6%
−61%
The challenge
A tier-1 supplier was launching its first battery module line against a fixed customer start-of-production date. The plan allowed 16 weeks to reach rate, and the plant’s previous launch had run late.
What we did
We joined at the specification stage and put the vendors, the integrator and the plant team on one weekly schedule. Before start-up we ran a two-week trial build to time every station, then fixed the screwdriving station and the end-of-line test sequence before volume arrived.
Operators trained on the real line, not on slides, two weeks before the first customer parts.
The result
The line reached rate in 10 weeks instead of 16, and scrap fell from 4.1% to 1.6% over the same period. Both numbers are tracked in the plant’s own morning review, not in our report.
The numbers held after they left. That had never happened on this line before.
Plant manager
Battery module line
Next step
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