Challenge
The client was developing a revolutionary commercial EV receiving strong market feedback. Despite decades of automotive experience and technical expertise in product design, this was their first full vehicle launch. As the project neared production, leadership identified a growing disconnect between optimistic program status reports and the actual level of readiness they observed — concluding they needed a different approach to orchestrate the people, parts, equipment, and processes for a smooth launch.
KEY RESULT
Built launch-ready manufacturing process from virtual build to validated production plan
KPI
99.5% inventory accuracy
SERVICE
Launch Readiness Assessment, Program Management Recovery
DURATION
7 months
Results
Performed virtual and slow builds to create the value stream map, identify build and design issues, and create operator instructions
Hired and onboarded the manufacturing quality department
Achieved 99.5% inventory accuracy after managing material receipt with hundreds of running changes while simultaneously implementing a new ERP system
Created a change control management tool to track engineering, purchasing, component status, obsolescence, rework planning, and inventory movement
Implemented visual management tools for manufacturing engineering
Created an animated simulation of the entire 2-building manufacturing process to validate cycle times, ergonomics, and staffing needs
Documented a credible plan for a path to launch: clean bill of materials, supply chain status, timeline, and fully populated active issues list
Trained the entire project team for accountability to execute the plan
In the client's own words, RPM "not only excels in pinpointing problems, but also stands out for their aptitude in recommending effective solutions" — and was at the forefront of implementing those solutions. The client shifted from uncertainty to clarity, with a credible plan to bring their innovative new EV product to market.
