Our client is a Tier 1 supplier and leading manufacturer of metal castings for the automotive, commercial vehicle, and industrial markets. The company produces high-quality cast components through both iron and aluminum casting processes.
The client sought to optimize throughput and operational efficiency across its machining operations, but several legacy practices were holding production back. Machine selection often prioritized immediate needs over optimal performance, creating cycle time delays and capacity inefficiencies. CNC programming inefficiencies, including daisy-chained part programs, extended quality adjustments and lengthened cycle times, while fixtures designed primarily for single-piece operations limited flexibility and throughput. Operator variability complicated quality checks, and changeover tracking suffered as setup personnel were frequently diverted to other tasks. The absence of dedicated changeover resources and standardized processes left the operation with limited visibility into where time was being lost.
Leadership needed a partner who could quickly identify the highest-leverage opportunities, optimize machining and tooling capability, and put in place the discipline required to sustain higher throughput long-term.
MS Companies deployed a customized improvement approach focused on machine capability, throughput, and operational discipline, delivering measurable change in just four weeks. Focus areas included:
After failing two consecutive audits, a Tier 2 supplier turned to MS Companies for Quality Representation support. Within 20 business days, the advisor helped close 53 of 54 audit findings,
When a Tier 1 supplier faced back-to-back production crises, MS Companies’ on-site liaison stepped in to coordinate facilities, identify root causes, and keep assembly lines running.
Faced with an urgent workforce shortage, a Tier 1 automotive supplier partnered with MS Companies to deploy 528 temporary workers under the Crisis Labor Model.
